Tuttnauer 2540 EHS, 3870 EHS Technician Manual

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Page 1

TECHNICIAN

MANUAL

Electronic Table - top

Pre and Post Vacuum Autoclaves

models 2540 & 3870 EHS

Cat. No. MAN205-0063-005E Rev. D

Page 2

TABLE OF CONTENTS

PARAGRAPH PAGE NO.

1 INTRODUCTION..................................................................................................4

2 SYMBOL DESCRIPTION ....................................................................................4

3 INSTALLATION INSTRUCTIONS .....................................................................5

3.1 Site requirements for installation of a 2540 EHS

.......................................

3.2 Site requirements for installation of a 3870 EHS

.......................................

3.3 Suggested Site Drain Drawing

.....................................................................

3.4 Electrical Specifications

...............................................................................

3.5 Placing the Autoclave

...................................................................................

3.6 Connections to Utility Supplies

....................................................................

3.7 Installation Tests

........................................................................................

3.8 Water Quality

..............................................................................................

4 DESCRIPTION OF THE CONTROL SYSTEM. ..............................................12

4.1 System Summary

........................................................................................

4.2 Keyboard

.....................................................................................................

4.3 Digital Board DIG - T2

..............................................................................

4.4 Analog Board ANL-T2

...............................................................................

4.5 AC - Board - AC-T1

....................................................................................

5 CALIBRATION OF PRESSURE AND TEMPERATURE ...............................19

5.1 Calibration Overview

..................................................................................

5.2 Calibration Theory - Error Compensation:

..............................................

5.3 Equipment needed for calibration

.............................................................

5.4 Calibration Procedure

................................................................................

6 TESTING AND RESETTING.............................................................................26

6.1 Test Points

...................................................................................................

6.2 In – Out Test mode:

....................................................................................

6.3 Resetting the Autoclave:

.............................................................................

6.4 Input Output Graph:

..................................................................................

7 PROPERTIES OF SATURATED STEAM ........................................................ 35

8 SOFTWARE PROGRAMMING PARAMETERS .............................................36

8.1 General

........................................................................................................

8.2 Changing Parameters

.................................................................................

9 MAINTENANCE AND REPLACEMENT PROCEDURES .............................47

9.1 Safety Tests after Repair

............................................................................

9.2 Removing the Autoclave’s Outer Covers

...................................................

9.3 Replacing the Safety Valve

.........................................................................

Page 3

TABLE OF CONTENT (Cont.)

PARAGRAPH PAGE NO.

9.4 Replacing the DIG-T2 board

......................................................................

9.5 Drain Valve Repair

.....................................................................................

9.6 Replacing the Pressure Gauge

...................................................................

9.7 Replacing the Door Bellows (Located in the door bridge)

........................

9.8 Replacing the Printer

.................................................................................

9.9 Replacing the Door Switch

.........................................................................

9.10 Replacing the circuit breaker

.....................................................................

9.11 Replacing the water pump

..........................................................................

9.12 Pressure Switch

..........................................................................................

9.13 The Heaters

.................................................................................................

9.14 The Dual Compartment Water Reservoir

..................................................

9.15 The Water Sensing Electrodes

...................................................................

9.16 The Vacuum Pump

.....................................................................................

9.17 Draining the Jacket

....................................................................................

9.18 Replacement of the Door Cover

.................................................................

9.19 Replacing the Closing Device

....................................................................

9.20 PT100 Temperature Sensor Replacement

.................................................

10 TROUBLESHOOTING .......................................................................................72

10.1 Preliminary Check

......................................................................................

10.2 Preliminary Troubleshooting

.....................................................................

10.3 Pre-process malfunction

............................................................................

10.4 In Process Malfunction

..............................................................................

10.5 Mechanical malfunction

..........................................................................

111

10.6 Water pump malfunction

.........................................................................

113

11 SPARE PARTS LIST......................................................................................... 114

12 VALVES NUMBERING....................................................................................124

Page 4

TABLE OF CONTENT (Cont.)

DRAWINGS PAGE NO.

REAR VIEW

..................................................................................................................

CONTROL SYSTEM BLOCK – DIAGRAM

............................................................

DIG- T2 BOARD

.........................................................................................................

ANL- T2 BOARD

........................................................................................................

AC-T1 BOARD

............................................................................................................

EXTERNAL CONNECTION OF THE 2540EHS AUTOCLAVES ELECTRONICS

BOX

...............................................................................................

117

EXTERNAL

CONNECTION OF THE 3870EHS AUTOCLAVES

ELECTRONICS BOX

...............................................................................................

118

VESSEL ASSEMBLY

...............................................................................................

118

VESSEL ASSEMBLY

...............................................................................................

119

OUTER CABINET – ASSEMBLY

...........................................................................

120

TRAY HOLDER

........................................................................................................

121

TRAY

.........................................................................................................................

122

TRAY HANDLE (CMT240-0001)

............................................................................

122

DOOR TIGHTENING BOLT – ASSEMBLY

..........................................................

123

PIPING DRAWING FOR 2540 EHS

.......................................................................

125

PIPING DRAWING FOR 3870 EHS

.......................................................................

126

ELECTRICAL DRAWING FOR 2540 EHS

............................................................

127

ELECTRICAL DRAWING FOR 3870 EHS (TILL S/N 2307039)

..........................

128

ELECTRICAL DRAWING FOR 3870 EHS (AFTER S/N 2307040)

......................

129

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1 INTRODUCTION

This Technician’s Manual, together with the Operator’s Manual, forms the

complete set of Operation and Maintenance instructions for the EHS pre and post vacuum autoclave. This manual is intended for the use of the technician. It is strongly recommended that only qualified and Tuttnauer factory trained personnel service this autoclave and do so in accordance with the instructions in this manual. Any unauthorized service may result in the invalidation of the manufacturer’s warranty.

2 SYMBOL DESCRIPTION

Caution! Consult accompanying documents

Caution! Hot surface.

Caution! Hot steam.

Protective earth (Ground)

Stand by

Page 6

3 INSTALLATION INSTRUCTIONS

For proper operation, these are the required utilities that need to be

supplied for each model EHS:

3.1 Site requirements for installation of a 2540 EHS

Caution The sterilizer must be placed on a rigid and leveled surface and must be able to hold the weight of the device and loaded material.

1. Counter top able to support a minimum 200 lb. * (the unit is shipped with a suitable stand - 26”W x 33”D x 34”H)

2. Counter space minimum 20”W x 32”D x 20”H * (see unit dimensions below)

3. City water supply 15 - 58 psi with shut off valve having ½" NPT male end.

Higher rates of pressure will require the installation of a pressure

reducer (58 psi max).

A regulator and pressure gauge are supplied with the unit

The minimum flow rate required is 0.66 gal/min. (2.5 lit./min.).

Installation of the valve should be 2" above counter height at the

rear of the unit.

4. Mineral Free water supply 7 - 30 psi with shut off valve and ½" NPT male end.

Higher rates of pressure will require the installation of a pressure

reducer.

A regulator and pressure gauge are supplied with the unit

The minimum rate of flow is 0.26 gal/min (1 lit/min).

Installation of the valve should be 2" above counter height at the

rear of the unit. * (an optional R.O. water system is available).

5. Electrical power 20A – 208V single phase. Connection required; flush mount receptacle 6-20R, within 1 foot of the rear of the unit.

6. Drainage should be to a 4” high 4” diameter air break, reducing down to a 1 ½” vented line with a trap. All drainage components must be able to withstand a non-continuous temperature of 140°F (60°C). Drain opening should be within 1 foot of the rear of the unit and no higher than 16” above the floor. The use of two ½”x 6" Milford Type Copper Coated Hangers is required for the positioning of the two drain hoses over the center of the air break and a 4” metal worm gear clamp to secure the hangers. The hangers will need to be bent at a 90º angle to allow for proper positioning and securing with the clamp. * (see attached drawing)

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3.2 Site requirements for installation of a 3870 EHS

Caution The sterilizer must be placed on a rigid and leveled surface and must be able to hold the weight of the device and loaded material.

1. Counter top able to support a minimum 400 lb. * (the unit is shipped with a suitable stand - 26”W x 33”D x 34”H)

2. Counter space minimum 26”W x 39”D x 24”H * (see unit dimensions below)

3. City water supply 15 - 58 psi with shut off valve having ½" NPT male end.

Higher rates of pressure will require the installation of a pressure

reducer (58 psi max).

A regulator and pressure gauge are supplied with the unit

The minimum flow rate required is 0.66 gal/min. (2.5 lit./min.).

Installation of the valve should be 2" above counter height at the

rear of the unit.

4. Mineral Free water supply 7 - 30 psi with shut off valve and ½" NPT male end.

Higher rates of pressure will require the installation of a pressure

reducer.

A regulator and pressure gauge are supplied with the unit

The minimum rate of flow is 0.26 gal/min (1 lit/min).

Installation of the valve should be 2" above counter height at the

rear of the unit. * (an optional R.O. water system is available).

5. Electrical power 20A - 208V three phase, three power lines plus a ground. Connection required; flush mount receptacle or drop line with NEMA # L15-20R, this is a twist lock connector, within 1 foot of the rear of the unit.

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3.3 Suggested Site Drain Drawing

Caution! Wastewater should be brought into the public sewage network in

accordance with the local rules or requirement i.e. only nonhazardous liquids shall be disposed of in public sewage!

Network and connection should comply with the devices

consumption, local installation and safety rules and regulations.

Discharge hoses from EHS

Hanger with 90º ben

Coated Hanger

4” x 4” PVC air brea

1 ½” PVC To trap

4” Metal worm gear clamp

Milford Type Copper

Page 9

3.4 Electrical Specifications

Value

Property

2540 3870

Heaters Power 3000W 6000W

Total Power 3200W 6200W

Voltage (V) 1 ph / 208 3 ph / 208

Amperage (A) 15 15

Frequency (Hz) 50/60 50/60

Protection against electrical shock Class I (IEC 60601-1)

Note: In order to avoid any injury by electrical hazard, it is

recommended that a ground fault protection device be installed in the electrical panel feeding the autoclave (local codes may make this mandatory).

3.5 Placing the Autoclave

Set the rear legs so that the chamber pitches down in the front at a rate

of 1/8” per foot. This ensures that water is completely drained out of the chamber through the opening at the bottom front of the chamber. To check, pour a glass of water into the bottom rear of the autoclave and observe the water flow out of the chamber.

NOTE: Keep the back and the sides of the autoclave

approximately 1” (25 mm) away from the wall to allow ventilation.

It is recommended that enough space be left around the autoclave

to give a technician access for servicing the machine.

3.6 Connections to Utility Supplies

Using the ½” hoses and washers supplied with the unit

1. Connect the tap water inlet on the back of the autoclave to the feedwater supply (city water supply).

2. Connect the mineral -free water inlet on the back of the autoclave to a source of mineral-free water.

3. Connect the exhaust outlet on the back of the autoclave (using the black hose supplied with the unit) to a suitable drain as described above. Be sure to observe local codes for discharge of this type.

Note: The drain hose from the exhaust outlet must be fixed very

securely to the drain, ensuring that when steam and water are exhausted the hose is not allowed to recoil and cause injury to personnel.

4. Connect the reservoir overflow on the back of the autoclave to a suitable drain as described above.

5. Plug the power cord into the supply socket.

Attention! The pressure of the jacket does not decrease when the

equipment is turned off.

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REAR VIEW

Page 11

3.7 Installation Tests

At the time of installation, before the autoclave can be okayed for daily operation the service technician needs to perform the following preliminary checks:

♦ Integrity check: perform a visual check to verify that there are no

dents, scratches or broken components on the autoclave

♦ The leakage current check: test the precise operation of the earth

leakage relay

♦ Ground check: test the continuity of the grounding connection

♦ Power supply check: check that proper power is being supplied to

the machine. See sec. 3.4.

♦ Pitch check: confirm that the autoclave has a downward pitch back

to front of 1/8" per foot. (see sec. 3.5)

♦ Exhaust and Feed hose check: ensure that all hoses are free

flowing and not restricted.

♦ Water Pressure Check: verify that the city water pressure into the

unit is between 15 - 58 psi. Verify that the mineral free water pressure into the unit is between 7 - 30 psi.

♦ Door check: ensure that the door locking mechanism is

functioning properly

♦ Reset the Unit: turn power off using the green power button at the

bottom of the front panel, press and hold the Sel. Cycle button on the keypad, turn power on, continue to hold the Sel. Cycle button until the message Program Wait appears on the screen.

♦ Atmospheric Pressure check: the unit is set from the factory at

14.5 psia, this is atmospheric pressure at sea level. If the unit is located more that 500 ft above or below sea level then the Atmos. Press parameter must be set, see sec 8.2.17

♦ Safety Valve check: test the safety valve as per the instructions in

sec 8.6 of the Operator's Manual

♦ Cycle check: run a B&D Test to ensure that all systems in the unit

are functioning properly.

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

daily operation

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3.8 Water Quality

3.8.1 Built-in Steam Generator

The distilled or mineral – free water supplied to the steam

generator shall be according to the table below:

A Reverse Osmosis system meeting the qualifications below

may be used to provide water for the steam generator. The better the quality of the water, the better performance, the less maintenance and the longer the life of the autoclave.

Mineral Free Water qualifications

(In compliance with ISO 11134 and ISO 13683)

Evaporate residue

≤ 15 mg/l

Silica

≤ 2 mg/l

Iron

≤ 0.2mg/l

Cadmium

≤ 0.005 mg/l

Lead

≤ 0.05 mg/l

Rest of heavy metals

≤ 0.1 mg/l

Chloride

≤ 3 mg/l

Phosphate

≤ 0.5 mg/l

Conductivity

≤ 50 µs/cm

6.5 to 8

Appearance

Colorless, clean, without sediment

Hardness

≤ 0.1 mmol/l

Attention: The use of water in the autoclave that does not comply with

the table above may have severe impact on the working life of the sterilizer and can invalidate the manufacturer’s warranty.

The suitability of the mineral free water to be used should be

verified by testing in accordance with the above table; at an authorized laboratory using acknowledged analytical methods. We recommend testing the water quality once a month.

3.8.2 Water for the Vacuum System and the Drain Cooling

The feed water supplied, typically from a public water system,

to the liquid ring vacuum pump must meet the following requirements:

♦ Hardness: 0.7 - 2 mmol/l.

♦ Water temperature: shall

not exceed 59°F (15°C).

Note: The use of hard water in the vacuum pump may invalidate

the warranty for the vacuum pump, since it can cause blocking of the rotor, which can damage the pump.

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4 DESCRIPTION OF THE CONTROL SYSTEM.

4.1 System Summary

The hardware portion of the control system consists of a keyboard and

3 additional electronic boards designed specifically to match the requirements of the EHS autoclave. The main board is the digital board, DIG-T2, which contains the microprocessor and is responsible for controlling the system. The analog board, ANL-T2, interfaces with the DIG-T2 board and the various system components processing signals traveling to and from these areas. The AC-T1 board consists of AC power filters and drivers for the AC components in the system. DC power (12V and 5V) for all the DC components is supplied by a switching type power supply. In addition the system is capable of direct communication with a printer over a parallel interface and/or a PC via an RS 232 port (for more detail see individual descriptions below).

CONTROL SYSTEM BLOCK – DIAGRAM

The following paragraph applies only to the 3870EHS

From S/N 2307040, a Varistor is connected, in parallel, to each of the

SSR’s contacts, in order to decrease the voltage spikes, caused by the operation of the power devices (pumps and heating elements).

In the 3 phase system (in our case, the 3870EHS) the current, to the

heating elements, is supplied via a contactor. A “CUT OFF” thermostat is connected to the contactor's coil. If the temperature of the heating elements exceeds the alarm value, the “CUT OFF” thermostat disconnects the contactor coil, the contactor's contacts open ("off" position) and the heating elements are disconnected from the electrical power.

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4.2 Keyboard

The keyboard is mounted to and directly connected to the DIG-T2

board and functions as an MMI (Man-Machine Interface). The keypad serves as a control panel containing the command and programming keys. It also includes an LCD display with two rows of 16 characters for cycle progress updates and error messages. In addition it contains the following light indicators:

— START (autoclave in process),

— FAIL (the process failed),

— WATER (no water in the reservoir),

— DOOR (blinks with buzzer sound when START is

pressed and the door is not closed).

For more detail on the control keys and error messages please see the

EHS Operators Manual

4.3 Digital Board DIG - T2

The digital board contains the microprocessor that runs the system

software program and controls all the functions of the EHS autoclave. It is connected to the Keypad and digital display for interactive communication with the operator. It is also connected to the ANL-T2 analog board for communication with the rest of the EHS autoclave. In addition the DIG-T2 board has PC and printer communication abilities.

— The digital board is connected to the keypad and the ANL-T2

analog board via ribbon cables.

The DIG-T2 board receives human commands through the Keypad

and transmits visual information back, through the Keypad display

The DIG-T2 board receives sensory information, from system

sensors, in the form of digital signals through the ANL-T2 board. It also transmits operational commands, in the form of digital signals, to the various system components through the ANL-T2 board. Power for the DIG-T2 is provided by the ribbon cable connected to the ANL-T2

— The digital board also contains a parallel printer port for connection

to a proprietary printer. The printer is connected directly to this board through connector DS1 via a ribbon cable. The printer receives data and operating voltage directly from this connector.

— The PC interface establishes two-way communication between the

DIG-T2 board and a stand-alone personal computer, utilizing proprietary software. This communication is via a connector located on the ANL-T2 board and ribbon cable leading to an external connector on the front panel.

— On the board, are three types of memories:

1) EPROM memory (U15) for storing the program codes.

2) RAM memory (U9) with a capacity of 64KB for the storage of

temporary data during the running of the program that is located on the opposite side. This information is only for general knowledge.

Page 15

3) FLASH memory (U17) 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 a Real Time Clock element (U12), which

serves as a clock to the system. It includes a back-up battery, which ensures that the clock runs continuously even when the autoclave is not powered.

— The back-up battery RAM includes a 113-byte memory component

for storing the parameters currently in use.

— The board contains a solid-state component (U18) that acts as a

system watchdog. This component detects any faulty situation while the program code is running. It forces the micro-controller to recheck system inputs every 1.5 seconds, this prevents the software from becoming stuck in a program loop, that would lead to the software crashing and a loss of control of the machine.

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

DIG- T2 BOARD

— The system provides two types of communication with PC

software, RS232 and RS485. Jumpers on the DIG-T2 board need to be set differently for each type. The default is RS232 (see also ANL-T2 board):

1. RS232 – JP4, JP5, JP9 are closed. RS232 allows a single

communications port on the computer to communicate with a single EHS autoclave.

2. RS485 – JP7, JP8, JP10 are closed. RS485 allows a single

communications

port, with RS485 capability, to

communicate with multiple EHS autoclaves daisy chained together.

— The system is equipped with a hardware-reset switch (S1).

Page 16

4.4 Analog Board ANL-T2

The analog board contains the DC power transistors that drive the

valves, heaters and pumps. It contains the sensor circuits that decode the information from the temperature and pressure sensors before passing that information on to the DIG-T2 board. All the systems electronic components are connected through the ANL-T2 board. The analog board is connected to the AC-T1 board that controls the AC voltage devices. The power supply supplies 12 VDC and 5 VDC to the analog board and the ANL-T2 distributes that power to the remaining electronic components.

— JP1 & JP5 are connected to the two MPX2200 pressure sensors that

measure the chamber & jacket pressure.

— JP2 receives the digital input from the PT-100 temperature sensor

— JP8 is connected to the Power Supply and receives the 12VDC and

the 5VDC.

— JP6 provides a connection to the DIG-T2 board

— JP7 provides a connection for the Test Point board needed in

troubleshooting.

— JP9 provides control for the cooling fan

— JP10 connects the DC output drivers to the solenoid valves.

— JP11 is connected to the various digital inputs, such as the water

electrodes, door switch, float switches, etc.

— JP12 is directly connected to the SSR controlling the heaters. It

also provides a digital connection to the AC_T1F board, which controls the water and vacuum pumps and the steam valve.

— JP13 is not applicable in the EHS Machine.

— JP14 is not applicable in the EHS Machine.

— JP15 is used to match the communication connector configuration

to either RS232 or RS485. The default is RS232 (see also DIG-T2 board):

1. RS232 – JP15, short pins 2 & 3, 4 & 5.

2. RS485 – JP15, short pins 1 & 2, 3 & 4.

— P2 provides a link to the serial port on the front of the unit, via a

ribbon cable.

Page 17

Layout diagram of the ANL-T2 is provided below.

ANL- T2 BOARD

Top View

Bottom View

Page 18

4.5 AC - Board - AC-T1

The AC-T1 board provides AC filtering to protect the power supply

and the control system from voltage spikes. This board contains the AC voltage drivers that control the AC devices in the system. This is done by accepting command signals indirectly from the DIG-T2 board through the ANL-T2 analog board and then turning the devices on or off.

The AC-T1 board includes:

— A filter circuit utilizing the L1C5 isolation transformer.

— JP2 provides filtered power to the power supply.

— Three 230/115 VAC triac control circuits. These are the AC

drivers used in controlling the water and vacuum pumps and the steam valve.

— The maximum amperage this board is capable of controlling is 6A.

— Spike protection is provided by three components, RV1, RV2 and

RV3. These components provide a resistibility proportional to the spike level. The resistibility decreases when the spike level increases, so that the current will be transferred to the ground instead of damaging the autoclave’s system.

— JP1 is the control signal input from the ANL-T2 board

— JP3 is the AC input connector.

— JP4 is the output to the steam valve if an AC valve is used

— JP7 is the output to the water and vacuum pumps

Page 19

AC-T1 BOARD

Top View

Bottom View

Page 20

5 CALIBRATION OF PRESSURE AND TEMPERATURE

5.1 Calibration Overview

The calibration of temperature and pressure is performed digitally. This

system does not have adjustment pots. All calibrations are preformed through the keypad. The calibration procedure is identical on all EHS models.

The electronic temperature and pressure measuring circuits built into

the EHS are designed with components having 1% accuracy.

The pressure circuit produces a linear output and has an electrical

output range of 100mv - 2400mv, which corresponds to a pressure range of 0 - 58 psia.

The temperature circuit also produces a linear output and has an

electrical output range of 100mv - 2400mv, which corresponds to a temperature range of 68°F (20°C) - 302°F (150°C).

The temperature and pressure circuits provide analog input voltages

that are converted to digital signals by the A/D converter. The performance of the Analog to Digital converter (A/D) is limited for values greater than 2400mv or less than 100mv.

The system has a non-volatile memory in which the offset and gain

data of the sensors are stored, as well as any error compensation factors that are calculated. Storage in the no-volatile memory means that even if the main power is turned off the information is saved for use the next time the machine is run.

Calibration is performed by entering data through the keypad or a

stand-alone computer when the PC communication port is used.

Page 21

5.2 Calibration Theory - Error Compensation:

The system’s error compensation is based on a calculation involving

two points. These points represent the low and high end of the autoclaves operating temperature or pressure range.

Each point has two values; one value is the “A” actual (measured)

reading of either temperature or pressure (from a PT simulator, independent thermometer or pressure gauge). The other value is the “R” the reading from the autoclave’s digital display of either temperature or pressure. By entering these values into the unit through the keypad the system is able to calculate a compensation factor that will correct the digital display and allow it to accurately return the actual temperature or pressure.

Note: The two points that are selected will define the range of the error

compensation. Although points above and below are not part of the compensation, the calibration produces a linear compensation and these values will be accurate.

Note: The temperature can be calibrated in either °F or °C, depending

on what units the machine is set to display.

Note: The pressure calculations are always done in Absolute pressure

(Absolute pressure = atmospheric pressure + 14.5)

The calibration steps that follow will allow you to automatically

correct the displayed temperature and pressure so it accurately reflects the actual temperature and pressure. All you need do is input the appropriate data (actual and displayed values) into the system through the keypad and the on board computer will do the rest.

Note: It is necessary to know the actual and displayed values prior to

entering the calibration mode.

5.3 Equipment needed for calibration

— A PT100 simulator

— Saturated Steam Table (para 7)

5.4 Calibration Procedure

Calibration consists of three (3) parts and needs to be preformed in the

following order. It is not advisable to perform only a partial calibration

1. Check that the atmospheric pressure parameter is set correctly (see sec 8.2.17)

2. Collect and enter temperature data

3. Collect and enter pressure data

5.4.1 Connecting the test equipment

Remove the outer cabinet Disconnect the PT100 temperature sensor from the JP2

connector on the ANL_T2 board

Connect the PT100 simulator to JP2

Page 22

5.4.2 Collecting and entering temperature data

When collecting data, keep in mind that “A” is always the

actual temperature and “R” is always what is being displayed on the digital screen of the autoclave.

Once in the calibration mode, the calibration screen will look

similar to this:

Upper Row: A 140.0 R 140.0 (lower temp reading °F)

Lower Row: A 266.0 R 266.0 (higher temp reading °F)

When entering data, remember that the upper row will

represent the lower temperature of the chamber and the bottom row will represent the higher temperature of the chamber.

5.4.2.1 Collecting temperature data

— Select the low setting on the PT100 simulator

(it is suggested to use 158°F)

This will be the “A” value for the upper row.

— Record the temperature displayed on the screen

(there can be a slight delay in updating the screen when changing values on the PT100 simulator)

This will be the “R” value for the upper row.

— Repeat this procedure for the high setting using

the PT100 simulator (it is suggested to use 266°F)

These values will be for the bottom row

— Once the data is collected disconnect the PT100

simulator from JP2 and reconnect the PT100.

5.4.2.2 Entering temperature data

Access the calibration mode as described in para

5.4.4.

— The cursor will appear flashing under the value

for “A” in the upper row.

— Using the UP/DN arrow keys, enter the value

for “A”. This will be the first temperature value that the PT100 simulator was set for.

— Press the PROGRAM key to advance to the

next value.

— The cursor on the upper row will move one

position to “R”; now enter the first temperature value recorded from the display

— Press the PROGRAM key to advance to the

next value that will be in the bottom row.

— The cursor will be positioned under the value

for “A” in the bottom row.

Page 23

— Enter the value for “A”. This will be the second

temperature value that the PT100 simulator was set for.

— Press the PROGRAM key to advance to the

next value.

— The cursor on the bottom row will move one

position to “R”. Now enter the second temperature value recorded from the display

— Press the PROGRAM key one final time.

If PROGRAM WAIT has not been displayed

then continue to press the PROGRAM key until it appears.

After a brief period the unit will return to a

Ready state

5.4.3 Collecting and entering pressure data

When collecting data, keep in mind that “A” is always the

actual pressure and “R” is always what is being displayed on the digital screen of the autoclave. Under normal circumstances calibration only needs to be done at the high end of the pressure range.

Once in the calibration mode, the calibration screen will look

similar to this:

Upper Row: A 15 R 15 (atmospheric pressure reading)

Lower Row: A 45 R 45 (high pressure reading)

When entering data, remember that the upper row represents

atmospheric pressure and the bottom row represents the high pressure of the chamber. And that all entrees are in absolute pressure.

“If the display reads a chamber pressure of 00, with the door

of the autoclave open, then proceed directly to 5.4.3.2.

If the reading is not 00 then proceed as follows.

5.4.3.1 Atmospheric pressure calibration

Set the Atmospheric pressure parameter (see 8.2.17)

— If the read out on the display is at least 1psi

above or 1Ih below 00 then access the calibration mode as described in para 5.4.4

The cursor will appear flashing under the value

for “A” in the upper row.

— Press the Program key to advance to the next

value “R” in the upper row

Page 24

— Using the UP/DN arrow keys raise the value of

“R” if the display reads high. Lower the value of “R” if the display reads low.

(Example: if the display reads 2 psi, then raise

the value of “R” by 2; if it reads 2Ih then lower the value of “R” by 2)

— Press the program key until PROGRAM WAIT

is displayed. The autoclave will recalibrate and return to the Ready state.

— If the display now reads 00, with the door of the

autoclave open, then continue on to sec 5.4.3.2”

5.4.3.2 Collecting pressure data

— Select a program with a sterilization

temperature of 273 °F (134 °C), make sure the door is closed securely and press START.

— Let the unit cycle to maximum pressure that will

be reached once the unit has entered the sterilization mode.

— Record the temperature and pressure from the

digital display.

— Abort the cycle by pressing the STOP key.

— Consult the Saturated Steam Table for the

Absolute pressure that corresponds to the temperature recorded in the previous step and record that value.

— Add 14.5 to the pressure reading from the

digital display and record this value

5.4.3.3 Entering pressure data

Access the calibration mode as described in para

5.4.4.

— The cursor will appear flashing under the value

for “A” in the upper row.

— Press the PROGRAM key to advance to the next

value.

— The

cursor on the upper row will move one

position to “R”.

— Press the PROGRAM key to advance to the next

value that will be in the bottom row.

— The cursor will be positioned under the value for

“A” in the bottom row.

— Enter the value for “A”. This will be the value

of absolute pressure recorded from the Saturated Steam Table

Page 25

— Press the PROGRAM key to advance to the next

value.

— The cursor on the bottom row will move one

position to “R”; now enter the pressure value recorded from the digital display to which you have already added 14.5.

— Press the PROGRAM key one final time

If PROGRAM WAIT has not been displayed then continue to press the PROGRAM key until it appears.

After a brief period the unit will return to a Ready state

This completes the calibration procedure for temperature e and pressure. A sterilization cycle should be performed to verify that the system is calibrated and running properly.

Page 26

5.4.4 Accessing the calibration mode

— With the unit turned on press the PROGRAM key.

— Pressing the PROGRAM key will bring you to its

first function of setting the system’s date the time.

— Setting the date and time can be bypassed by pressing the

PROGRAM key six times.

— On the seventh press of the PROGRAM key CODE:

∅∅∅ will be displayed.

— Advance the code to 011 by pressing the UP arrow key

(this is a technician level code) then press the PROGRAM key.

— Continue pressing the program key until CALIB CODE:

1∅∅ is displayed.

— Using the UP arrow key select CALIB CODE: 107.

— Press the PROGRAM key again until Program Wait is

displayed, this is an intermediate calibration phase. Once the program wait is completed TEMP CAL: ∅∅∅ will be displayed.

— Using the UP arrow key advance to TEMP CAL: ∅∅1

— Press the PROGRAM key again. This is the Temperature

Calibration mode and the data is ready to be entered

— Press the PROGRAM key one additional time and the

display will show PRESS CAL: ∅∅∅.

— Using the UP arrow key advance to PRESS CAL: ∅∅1

— Press the PROGRAM key again. This is the Pressure

Calibration mode and the data is ready to be entered

Page 27

6 TESTING AND RESETTING

6.1 Test Points

These test points are provided to assist in trouble shooting the

autoclave. A test point board is needed to be able to read these test points.

NU TP

FUNCTION

VALVE

TP1

GND

TP2

+5V DC

TP3

+12V DC

TP4

OUTPUT HEATERS 0V-Off; 5V-On

TP5

OUTPUT VACUUM PUMP 0V-Off; 5V-On

TP6

 

TP7

OUTPUT AIR INLET VALVE (43) 0V –CLOSE; 5V-OPEN

TP8

OUTPUT VACUUM VALVE (52) 0V –CLOSE; 5V-OPEN

TP9

OUTPUT

MINERAL FREE WATER TO

RESERVOIR (21)

0V-Off; 5V-On

TP10

OUTPUT WATER TO VAC PUMP (15) 0V-Off; 5V-On

TP11

 

TP12

OUTPUT STEAM TO CHAMBER (93) 0V –CLOSE; 5V-OPEN

TP13

OUTPUT SLOW EXHAUST (74) 0V –CLOSE; 5V-OPEN

TP14

OUTPUT DRAIN COOLING WATER (13) 0V-Off; 5V-On

TP15

OUTPUT WATER TO VAC PUMP RES. (14) 0V-Off; 5V-On

TP16

OUTPUT FAST EXHAUST (73) 0V –CLOSE; 5V-OPEN

TP17

OUTPUT WATER PUMP 0V-Off; 5V-On

TP18

 

TP19

 

TP20

 

TP21

INPUT TEMPERATURE-1 (PT100) 273ºF = 1.97V

TP22

INPUT JACKET PRESSURE 29.4 psi = 2.031V

TP23

 

TP24

INPUT CHAMBER PRESSURE 29.4 psi = 2.031V

0V = SATISFIED

TP25

INPUT LOW WATER ELECTRODE

2.5V = NOT SATISFIED

0V = SATISFIED

TP26

INPUT HIGH WATER ELECTRODE

2.5V = NOT SATISFIED

Page 28

6.2 In – Out Test mode:

To enter the test mode –

• Turn off the main power switch

• While pressing and holding the UP arrow key, turn on the main

power switch.

The output test starts immediately Each output (valves, heaters, pumps), will be activated and the name of

that device will be displayed. To switch from one output to another, press the UP arrow key. When all the outputs have been tested the input tests will begin again. To leave the In – Out test mode, turn off the main power switch.

DISPLAYED

NOTICE

ITEM ACTIVATED REMARKS

Heaters ON Heating Elements Heating elements are activated.

Pump On Vacuum pump

Pump is operating only if there is water in the vacuum pump reservoir

Water ON Water pump for jacket ULKA water PUMP operates.

Air On Air valve (43) Air valve is open.

Water Res On

Mineral free water reservoir valve (21)

Water valve to mineral free reservoir is open.

Exh Res On Vacuum exhaust valve (52) Vacuum exhaust valve is open.

Steam On Steam valve (93)

Steam valve from jacket to chamber is open.

Vacum Wtr On Water valve (15)

Water valve from reservoir to vacuum pump is open.

Door Lock ON Door locking solenoid

Door locking solenoid is activated (retracted). (only on units with an electric door lock)

Slow Ex On Slow Exhaust valve (74) Slow exhaust valve is open.

Exh Drain On Fast Exhaust valve (73)

Fast Exhaust valve from chamber to drain is open

Cool wtr On Cooling water valve (13)

Exhaust Cooling water valve is open

Electrd –h 0

Electrode senses water in the jacket

Electrd –h 255

High water level electrode

Electrode does not sense water in the jacket and activates the water pump

)continued on next page(

Page 29

DISPLAYED

NOTICE

ITEM ACTIVATED REMARKS

Electrd –l 0

Electrode senses water above minimum level in the jacket

Electrd –l 255

Low water level electrode

Electrode does sense water above minimum level in the jacket and disconnects heating elements

Door Sw “0” Door switch activated

Door Sw “1”

Door switch

Door switch not activated

Float -l “0” Float switch senses water

Float -l “1”

Lower mineral free float switch. (move the float switch and verify that it operates)

Float switch does not sense water and stops operation of water pump

Float –H “0”

Float switch senses water and closes valve 21

Float –H “1”

Upper mineral free float switch. (move the float switch and verify that it operates)

Float switch does not sense water and opens valve 21

6.3 Resetting the Autoclave:

Whenever it becomes necessary to restore the system to normal

operation, the system must be reset. This will remove corrupted data

from memory and restore a healthy program. On occasion other

situations require that a reset be preformed, they are as follows:

— When the machine is operated for the first time

— If the machine has been sitting unused for a long period of time.

— When the cycle has not been completed, as a result of a power

failure or manual stop

To reset the system; proceed as follows:

Turn power off using the green power button at the bottom of the front

panel, press and hold the Sel. Cycle button on the keypad, turn power

on, continue to hold the Sel. Cycle button until program wait appears

on the screen then release.

After resetting, the autoclave will be in the stand-by

mode

Page 30

6.4 Input Output Graph:

Page 31

Page 32

Page 33

Page 34

Page 35

Page 36

7 PROPERTIES OF SATURATED STEAM

(From Baumiester & Marks “Standard Handbook for Mechanical Engineers”

7th Edition)

Gauge

Pressure

Absolute Pressure

Temp °F

Gauge

Pressure

Absolute Pressure

Temp °F

14.7

212.00 31

274.44

213.03 32

275.80

216.32 33

277.13

217.44 34

278.45

222.41 35

279.74

225.24 36

281.01

227.96 37

282.26

230.57 38

283.49

233.07 39

284.70

235.49 40

285.90

237.82 41

287.07

240.07 42

288.23

242.25 43

289.37

244.36 44

290.50

246.41 45

291.61

248.40 46

292.71

250.33 47

293.79

252.22 48

294.85

254.05 49

295.90

255.84 50

296.94

257.08 51 65 297.97

259.28 52

298.99

260.95 53

299.99

262.57 54

300.98

264.16 55

301.96

265.72 56

302.92

267.25 57

303.88

268.74 58

304.83

270.21 59

305.76

271.64 60

306.68

273.05

Page 37

8 SOFTWARE PROGRAMMING PARAMETERS

8.1 General

The software version that runs the control system of the EHS autoclave

can be found by turning the unit on and watching the display. The

version number is also printed if a printer is installed. The software contains a table of parameters of which some of them

define the autoclave, and some of them define the processes in the

autoclave. This section of the manual describes the parameters and how

they control the software.

8.2 Changing Parameters

An access code is needed to change any parameters other than the date

and time. Two access codes are currently available and each one gives a different

level of access. Access code 1 – This is the first level of access. This code enables

changing of the sterilization time, sterilization temperature and the drying time. This level of access is suitable for a senior office person in the medical facility.

Access code 13 – This is the second level of access. This code is for the

technician and allows access to make changes such as

calibrations.

To change the parameters listed below, proceed as follows:

a. Select the program cycle, to be modified, by pressing the

SEL.CYCLE key.

b. Press the PROGRAM key until CODE: ∅∅∅ appears

c. Using the UP/DN keys enter the access code for the level of access

desired. (i.e. CODE:013)

d. Select the parameter to be modified, by pressing the PROGRAM

key until the parameter name appears on the display.

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

f. Pressing the PROGRAM key will enter the modified data into

memory, and move to the next parameter.

g. When finished press the PROGRAM key until the message

PROGRAM WAIT appears. The software is reprogramming itself with the modifications that were made.

Note: Each of the 6 program cycles has a set of the following

parameters. Changing a specific parameter in one program will not change it any other program.

Listed below are all the available parameters for the EHS. Each section

describes the parameter, shows the access code required to be able to

make modifications, it shows the minimum and maximum allowed

values and the increments (resolution) by which these values can be

changed. Also included are the pre-set values of the parameters for

each cycle. Note: If a parameter is modified the only way to return to the original value is

to manually reenter it.

Page 38

8.2.1 SteTemp – Temperature required for sterilization

This parameter will set the desired temperature for sterilization

Access Code - 1

Resolution - 1ºF

Minimum value - 250ºF

Maximum value - 280ºF

Cycle

1 2 3 4 5 6

Default Values

Value

273 273 250 273 273 -

8.2.2 Ster Time – Time required for sterilization

This parameter will set the time desired for sterilization

Access code - 1

Resolution - 1 minute

Minimum value - 3 minute

Maximum value - 59 minutes

Cycle

1 2 3 4 5 6

2540

3.5 8 30 4 3.5 -

Default Values

Value

3870

3.5 8 30 8 3.5 -

8.2.3 Dry Time – Time required for drying

This parameter will set the time desired for drying

Access Code - 1

Resolution - 1 minute

Minimum Value - Ø minutes

Maximum Value - 59 minutes

Cycle

1 2 3 4 5 6

Default Values

Value

0 20 20 20 2 -

8.2.4 HeatT.O. – Sterilization temperature time out

This parameter will set the maximum time allowed, from the

beginning of the cycle, for the chamber to reach sterilization temperature. When the HeatT.O is exceeded, the program aborts

with the message ‘Low Heat’. Access Code - 13 Resolution - 30 seconds Minimum Value - 1200 seconds Maximum Value - 3180 seconds

Cycle

1 2 3 4 5 6

Default Values

Value

3000 3000 3000 3000 3000 0

Page 39

8.2.5 Ex.Mode – Rate of steam discharge during the exhaust stage

This parameter sets the rate at which steam is discharged during

the exhaust stage. Access Code - 13 Resolution - 1 Value - 1 or 4 Fast Exhaust = 1 Slow Exhaust = 4

Cycle

1 2 3 4 5 6

Default Values

Value

1 1 1 1 1 1

8.2.6 End Temp – Cycle End Temperature

This parameter sets the finish temperature of the exhaust stage.

The unit will signal a Cycle End only when the exhaust timer

has reached zero and the unit is below the End Temp. This also

indicates the proper time to open the door and unload the

chamber. Access Code - 13 Resolution - 1ºF Minimum Value - 104ºF Maximum value - 280ºF

Cycle

1 2 3 4 5 6

Default Values

Value

273 273 250 273 273 280

8.2.7 Puls num

.–

No. of vacuum pulses in the prevacuum stage

This parameter sets the number of vacuum pulses during the

prevacuum stage. Access Code - 13 Resolution - 1 Minimum Value - 1 Maximum Value - 7

Cycle

1 2 3 4 5 6

Default Value

Value

2 4 4 4 4 1

Page 40

8.2.8 Vac dip1

–

Vacuum value of the first vacuum pulse

This parameter sets the value of the vacuum that pulse no.1

needs to achieve in the prevacuum stage. This parameter is

expressed in psia (atmospheric pressure at sea level is =

14.7psia). A psia lower than 14.7 indicates a vacuum. (During a

cycle the autoclave displays vacuum as Ih (inches of mercury).

29.93 Ih = 14.7 psia (atmospheric pressure at sea level)) Access Code - 13 Resolution - .1 psi Minimum Value - 1 psia Maximum Value - 13 psia

Cycle

1 2 3 4 5 6

Default Value

Value

2.9 3.7 3.7 3.7 2.9 2.7

8.2.9 Vac dip2

–

Vacuum value of each of the remaining pulses

This parameter sets the value of the vacuum that the remaining

pulses (starting from pulse no. 2) need to achieve in the prevacuum stage. This parameter is expressed in psia (atmospheric pressure at sea level is = 14.7psia). A psia lower than 14.7 indicates a vacuum. (During a cycle the autoclave displays vacuum as Ih (inches of mercury). 29.93 Ih = 14.7 psia

(atmospheric pressure at sea level)) Access Code - 13 Resolution - 0.1 psi Minimum Value - 1 psia Maximum Value - 13 psia

Cycle

1 2 3 4 5 6

Default Values

Value

2.9 3.7 3.7 3.7 2.9 2.7

8.2.10 VacTime1

–

Waiting time at the end of the first pulse

This parameter sets the wait time at the end of the first vacuum

pulse, during the prevacuum stage. After reaching VacDip1,

there is a waiting time to allow the unit to stabilize. This time is

defined as VacTime1 and during this time the vacuum system

continues working. Access Code - 13 Resolution - 1 second Minimum Value - 3 seconds Maximum Value - 1800 seconds (30 minutes)

Cycle

1 2 3 4 5 6

Default Values

Value

3 3 3 3 3 3

Page 41

8.2.11 VacTime2

–

Waiting time at the end of each of the remaining

pulses

This parameter sets the wait time at the end of each of the

remaining vacuum pulses, during the prevacuum stage. After

reaching VacDip2, there is a waiting time to allow the unit to

stabilize. This time is defined as VacTime2 and during this time

the vacuum system continues working. Access Code - 13 Resolution - 1 second Minimum Value - 3 seconds Maximum Value - 1800 seconds (30 minutes)

Cycle

1 2 3 4 5 6

Default Values

Value

3 3 3 3 3 3

8.2.12 WtrResTime – Timed extension for pumping mineral free water

This parameter sets the length of time to continue pumping

mineral free water into the steam generator after the upper electrode senses water.

This is necessary to prevent a situation where the water pump

would cycle on and off as the water level rises and falls around

the upper water-sensing electrode. Access Code - 13 Resolution - 1 minute Minimum Value - Ø minutes Maximum Value - 90 minutes

Cycle

1 2 3 4 5 6

Default Values

Value

5 5 5 5 5 5

Page 42

8.2.13 limitP add

–

defines the upper limit of the pressure in the

jacket

This parameter is designed as a safety measure that defines the

maximum pressure in the jacket during heating and sterilization

stages. The maximum working pressure in he jacket is defined

as the pressure that correlates to the sterilization temperature

+ 5.4°F. Parameter limitP add allows to increase the pressure

above the maximum working pressure and defines the value of

this pressure. Caution: Setting this parameter to 4 psi may cause the Pressure Switch

and / or the Safety Valve to be activated.” Example: If the sterilization temperature is 273°F, the maximum pressure

will be 34 psig that correlates to 278.4°F (273°F + 5.4°F). If

limitP add is 2 the maximum allowable pressure will be 36. If

the pressure reaches the upper limit as defined by limitP add

(i.e. 36 in our example) the heating element will be switched off

and the pressure will begin to decrease. When the pressure

decreases below the maximum allowable pressure, the heating

element will be switched on again. Access Code - 13 Resolution - 0.1 psi Minimum Value - Ø psi Maximum Value - 4 psi

Cycle

1 2 3 4 5 6

Default Values

Value

0 0 0 0 0 0

8.2.14 Calib Code – Calibration Code 107

This parameter is used to set the calibration code. The correct

code is needed to calibrate the autoclave. After calibration the

code should be set back to the default value (100) to prevent any

unqualified person from altering the calibration Access Code - 13 Resolution - 1 Minimum Value - 0 Maximum Value - 255

Cycle

1 2 3 4 5 6

Default Values

Value

100 100 100 100 100 100

Page 43

8.2.15 ReqPrs+ - Overrides the pressure calculated for sterilization

This parameter is used to insure that during sterilization the

temperature is correctly maintained. It does this by raising the

value of the sterilization pressure necessary to maintain a

sterilization temperature. The sterilization pressure is calculated

by the unit based upon the SteTemp parameter. For example; if the required temperature is 250ºF, the required

pressure calculated by the program is 16 psig. This pressure can be increased by changing the value of

ReqPrs+. If this value is set to ø, the system will be maintained

at 16 psig during the sterilization stage if this value is set to 1.5,

the system will be maintained at 17.5 psig in the sterilization

stage. Access Code - 13 Resolution - 0.1 psi Minimum Value - Ø Maximum Value - 3 psi

Cycle

1 2 3 4 5 6

Default Values

Value

0.8 0.8 0.6 0.8 0.8 0

Page 44

8.2.16 Dry Vac

–

Pressure during the Dry Stage

This parameter is intended to control the vacuum pressure

during the Drying Stage. It does this by opening and closing the

Air Inlet Valve. In all cases the vacuum pump runs continuously

and the Jacket is heated until the end of the Dry stage, as set by

the Dry time parameter. This parameter is expressed in kpa, where 1 kpa = 0.145 psia Access Code - 13 Resolution - 1 kpa Minimum Value - 0 kpa Maximum Value - 90 kpa

If Dry Vac = 0, the Air Inlet Valve will be closed during the

Dry Stage. If Dry Vac is between 1 & 5, the Air Inlet Valve will be

operated in a shoot mode, 30 seconds open and 30 seconds

closed. This process will begin 4 minutes after the start of the

Dry Stage and continue until the Dry stage is completed If Dry Vac ≥6, the Air Inlet Valve will be used to regulate the

pressure during the Dry Stage so that the value of the pressure

will not fall below the Dry Vac value. E.g., if Dry Vac = 20 (1

kpa = 0.145 psia), then when the pressure reaches 2.9 psia, the

air valve will open and remain open until the pressure rises to

3.6 psia at which point is will close again. When the pressure

drops back to 2.9psia, the valve opens again to allow the

pressure to rise. This process continues until the end of the Dry

stage. In this example the pressure fluctuates between 2.9 psia

and 3.6 psia. The Air Inlet Valve is not working in a shoot

mode, but it opens and closes around the requested Dry Vac

value.

Cycle

1 2 3 4 5 6

Default Values

Value

5 5 5 5 5 1

Page 45

8.2.17 Atmos. Press

–

Atmospheric Pressure

This parameter tells the unit the atmospheric pressure of the

location in which it is installed. The pressure entered must be

with in 5% of the actual atmospheric pressure for that location.

Unlike the other parameters you only need to enter this

parameter once in any one cycle and all cycles will be updated. This value can easily be calculated by knowing the altitude of

your location. The atmospheric pressure at Sea Level is 14.5

psia. For every 100m above sea level, the atmospheric pressure

drops 0.14 psia, and for every 100m below sea level, the

atmospheric pressure increases 0.14 psia. Changes in pressure do to weather will not affect the accuracy

of this unit.

Access Code - 13 Resolution - 0.1 psi Minimum Value - 8 psia (for +4500m) Maximum Value - 15.7 psia (for –800m)

Cycle

1 2 3 4 5 6

Default Values

Value

14.5 14.5 14.5 14.5 14.5 14.5

8.2.18 PulsPress – pulse pressure during pre-vacuum stage.

This parameter is used to set the maximum pressure in each

pulse of the pre-vacuum stage. This parameter is expressed in

psia. During St.By (Stand By) and while running a cycle the

display shows pressure in psig. (Psig + 14.5 equals psia). Access Code – 13 Resolution – 1 psi Minimum Value – 7 psia Maximum Value – 30 psia

Cycle

1 2 3 4 5 6

Default Values

Value

22 23.5 23.5 23.5 23.5 23.5

Page 46

8.2.19 Heat Step – sterile temperature overshoot control

This parameter is used to reduce overshoot of the sterilization

temperature by controlling the sterilization pressure. The

sterilization pressure is calculated by the unit based upon the

SteTemp parameter. When the cycle starts the heating rate in

the chamber is constant until the pressure in the chamber

reaches the sterilization pressure minus the Heat Step. From

this point on heating is performed in pulses. Each pulse lasts

15 seconds and increases the pressure in the chamber by a

small amount until the proper sterilization pressure is reached. Access Code – 13 Resolution – 0.1 psi Minimum Value – 0.1 psi Maximum Value – 2 psi

Cycle

1 2 3 4 5 6

Default Values

Value

0.7 0.7 0.7 0.7 0.7 0.4

8.2.20 PresInPsig – selects the pressure display units.

This parameter sets the units of pressure that are printed by the

printer and used on the digital display during St.By (Stand By)

and while running a cycle. The two choices are psia (absolute

pressure) or psig / InHg (gauge pressure and inches of

mercury) Changing this parameter does not effect the units of

calibration used in any other parameter. Access Code – 13 Resolution – 1 Pressure is displayed in Psig and vacuum in InHg – 1 Pressure is displayed in psia – 0

Cycle

1 2 3 4 5 6

Default Values

Value

1 1 1 1 1 1

8.2.21 TempInC – selects the temperature units.

This parameter sets the units of temperature that are used by

the autoclave. Access Code – 13 Resolution – 1 Temperature is displayed in °C – 1 Temperature is displayed in °F – 0

Cycle

1 2 3 4 5 6

Default Values

Value

0 0 0 0 0 0

Page 47

8.2.22 Flash – Heating over-pressure control

This parameter is designed to regulate over pressure during the

heat up stage. The system constantly monitors the temperature

and pressure and compares both values to the Saturated Steam

Curve. If the pressure is found to exceed the corresponding

temperature by more than 0.7 psi then the fast exhaust valve is

opened for 1 second in an attempt to realign the temperature

and pressure. The system will wait 15 seconds and check

temperature and pressure again. If needed the fast exhaust will

be opened again for 1 second. This process will continue until

the temperature and pressure are correctly aligned.

Access Code – 13 Resolution – 1 Value – 0 or 1 If Flash = 0 This feature is not activated. If Flash = 1 This feature is activated.

Cycle

1 2 3 4 5 6

Default Values

Value

1 1 1 1 0 0

8.2.23 Auto. Num – Autoclave Identification number

This parameter is used to set the identification number relative

to other autoclaves in the facility. This number only appears on

the printout of a unit with a printer installed. It enables the

operator to link the printout with a specific autoclave. This

parameter need only be set once, while in any of the 6

programs. Access Code – 13 Resolution – 1 Minimum Value – 1 Maximum Value – 99

Page 48

9 MAINTENANCE AND REPLACEMENT PROCEDURES

9.1 Safety Tests after Repair

ATTENTION!

After every repair or dismantling of the enclosure, it is recommended that the following tests be performed:

1. Enclosure Current Leakage Test.

The test should be performed using a Megger. Make sure the

autoclave is unplugged. The electrical potential of the testing instrument should be 500V. The insulation resistance should be at least 2 MΩ.

The test is successful if there was no leakage.

2. Protective Earth Impedance Test

The test should be performed using an Ohmmeter. Make sure the

autoclave is unplugged from the wall outlet. Next measure the resistance between the grounding screw on the rear plate (or any other unpainted metallic part) and the grounding pin of the power cord plug. The resistance should not exceed 0.3 Ω, a high resistance would indicate a faulty ground connection.

Page 49

9.2 Removing the Autoclave’s Outer Covers

Caution! Before starting, disconnect the instrument from the power

source and ensure that there is no pressure in the chamber or jacket.

Allow the autoclave to cool before removing outer covers.

1. Remove the screws holding the rear cover (1).

2. Remove the screws holding the cover to the base (2).

3. Dismantle the air filter from the service opening cover (3).

3.1. Remove the screws holding the filter cover.

3.2 Disconnect the filter from the silicone tube

4. Remove the grounding wires from the cover.

5. Pull the cover upwards.

Note:

The following picture refers to model 2540

Page 50

9.3 Replacing the Safety Valve

The safety valve is installed to protect the Jacket from over

pressurizing should all the electrical controls fail.

Caution! Before starting, be sure that the electric cord is disconnected and that

there is no pressure in the chamber or jacket.

1. Take off the autoclave cover (see para. 9.2 “Removing the

Autoclave’s Outer Covers”).

2. Remove the water reservoir gasket.

3. Unscrew the safety valve and remove it from the safety valve base.

4. Replace the valve with a new safety valve (install only an original

equipment replacement!). Use a hydraulic sealant to seal the threads to ensure that the assembly is leak free.

5. Perform one cycle and verify that the valve operates correctly.

Page 51

9.4 Replacing the DIG-T2 board

The DIG-T2 board contains the software program and controls all the

functions of the autoclave. See sec 4.3.

Caution! Make sure that the power cord is disconnected! Allow the chamber and jacket to cool before removing outer covers.

Refer to the picture below when following this procedure.

1. Take off the autoclave cover (see para. 9.2 “Removing the Outer

Covers of the Autoclave”).

2. On model 3870 disconnect the flat cable from the printer.

3. Disconnect the flat cable from JP1-DIG-T2 to JP1 ANL-T2 (4).

4. Disconnect the flat cable from the PC port to P1-ANL-T2 (6).

5. Disconnect the green grounding cable (5).

6. Remove the screws that connect the plastic panel, housing the

DIG-T2 board, to the autoclave (2).

7. Disconnect the main switch (7).

8. Remove the DIG-T2 and keypad from the plastic panel.

9. Disconnect the DIG-T2 from the keypad.

10. Install a new DIG-T2 to the keypad and reinstall it into the plastic

housing

11. Follow the previous instructions in reverse to reassemble the unit

9.5 Replacing the Electronics Box Caution! Make sure that the power cord is disconnected! Allow the chamber and jacket to cool before removing outer covers.

Refer to the picture below when following this procedure.

1. Take off the autoclave cover (see para. 9.2 “Removing the Outer

Covers of the Autoclave”).

2. Remove the screws from the bottom and top of the electronic box

(1, 3).

3. Disconnect all the electric system connectors connecting the

electronic box to the base (including the MPX connectors).

4. Remove electronics box and replace with new one.

5. Re-assemble the instrument. Verify that the grounding connections

are connected correctly.

6. Test any cycle and verify that the autoclave operates as required.

Page 52

Electronic box: 3870

Electronic box: 2540

Control panel

7 2

63 2

1 1

Electronic

box

Electronic

box

1 17

2 3

Control panel

Page 53

9.5 Drain Valve Repair

There are two drain valves on the front of the autoclave. One drains the

mineral free water from the front section of the reservoir and the other drains the vacuum pump water from the back section of the reservoir.

Caution! Before starting, disconnect the instrument from the power source and

ensure that there is no pressure in the chamber or jacket.

Allow the autoclave to cool before removing outer covers.

9.5.1 Replacing the O rings

1. Open the manual drain cock on the front of the machine and drain any water left in the reservoir

2. Continue turning the drain cock in a counterclockwise direction. Some resistance will be felt, but eventually the drain cock assembly will come out.

3. Replace the two O rings on the drain cock (see drawing).

4. Reinstall the drain cock in the drain valve body by turning clockwise.

5. After a few turns press the large O ring (1) into the recess on the drain valve body.

6. Continue turning clockwise until the drain cock is seated.

Item Cat No.

1 SRV000-0224

2 SRV000-0232

Page 54

9.5.2 Replacing the drain valve assembly

1. Take off the autoclave cover (see para. 9.2 “Removing the Outer Covers of the Autoclave”).

2. Disconnect the drain tube from the valve, using a 9/16” wrench.

3. Remove the nut (3) and the “ring for drain valve” (2).

4. Remove the drain valve (1) from the panel.

5. Install a new valve according to the drawing below.

6. Verify that there is no leakage.

CMT240-0020 CMT240-0003 VLV170-0066

Page 55

9.6 Replacing the Pressure Gauge

Caution! Before starting, disconnect the instrument from the power source

and ensure that there is no pressure in the autoclave’s chamber and jacket.

9.6.1 Model 2540

1. Take off the door cover (see para. 9.18 Replacement of the Door Cover).

2. Remove the pressure gauge from the door by unscrewing it from the door

3. Install the new pressure gauge using Teflon tape to seal the threads. Verify that the gauge’s tube does not protrude from the doors inner surface.

4. Operate the autoclave and verify that there are no leaks.

5. Reinstall the door cover.

9.6.2 Model 3870

The gauge is located in the plastic housing adjacent to the door

and directly in front of the electronic box.

1. Take off the autoclave cover (see para. 9.2 “Removing the Autoclave’s Outer Covers”).

2. Disconnect the copper tube at the back of the gauge.

3. Remove the pressure gauge.

4. Install the new pressure gauge.

5. Reconnect the copper tube. (The copper tube uses a compression fitting so no Teflon tape is needed).

6. Operate the autoclave and verify that there are no leaks

7. Reassemble the autoclave’s cover

Page 56

9.7 Replacing the Door Bellows (Located in the door bridge)

The door bellows is designed to work with the closing device

providing a double lock that keeps the door closed while there is pressure inside the chamber.

Caution! Before starting, disconnect the instrument from the power source

and ensure that there is no pressure in the autoclave’s chamber.

1. Open the door.

2. Unscrew and remove the locking bolt (5).

3. Remove the Bellows assembly, using one of these two methods

3.1 Blow compressed air into the steam inlet hole on the inner surface of the door. This will cause the Bellows Assembly to pop out.

3.2 Gently pull out the door safety device locking pin (13). And using a bellows extraction tool, remove the bellows assembly.

4. It is possible that the washers (7, 10) will be stuck - if so, again use compressed air to blow them out or the bellow extraction tool to remove them.

5. Insert a new Door Bellows Kit (13,12,10,7) into the original brass sleeve (14), making sure to insert the kit into the narrower end of the sleeve. (No lubrication or cleaning is required.)

6. Insert the locking bolt (5) into the sleeve, making sure that the collar on the bolt fits into the sleeve.

7. Reinstall the completed assembly into the door bridge.

8. Tighten the locking bolt (5), it need not be super tight, just tight enough to properly seat the rear washer (7).

9. Run a test cycle and check for leaking.

LOK240-0026

LOK240-0025

LOK240-0022

Page 57

9.8 Replacing the Printer

Caution! Before starting, disconnect the instrument from the power source.

1. Take off the autoclave cover (see para. 9.2 “Removing the Autoclave’s Outer Covers”).

3. Disconnect the flat cable (1) connecting the printer to the DIG-T2 board.

4. Unscrew the two screws (2) fastening the printer to the panel.

5. Remove the printer and install the new one.

6. Verify that the printer is working by performing a self-test. This is done by pressing and holding the printer feed button and turning on the autoclave.

7. Run a cycle and verify that the printer operates correctly.

Page 58

9.9 Replacing the Door Switch

The door switch is designed to ensure that the door is properly closed

before and during a cycle.

Caution!

Before starting, disconnect the instrument from the power source

and ensure that there is no pressure in the autoclave’s chamber.

1. Take off the autoclave cover (see para. 9.2 “Removing the Autoclave’s Outer Covers”).

2. Disconnect the wires from the door microswitch.

3. Remove the microswitch and replace it with a new one.

4. Reconnect the black ground wire (2) to the microswitch.

5. Test the connection with an ohmmeter. Connect the ohmmeter to the common terminal of the microswitch (1) and chassis ground. In the “door open” position the ohmmeter should show no continuity and in “door close” position the ohmmeter should show a complete circuit.

5.1 If it fails the test then check that the ground wire is connected

to the correct terminal. If it is then replace the microswitch.

5.2 If it passes the test then connect the green wire from the

electronic box to the common terminal (1) of the switch

6. Reassemble the autoclave cover.

Page 59

9.10 Replacing the circuit breaker

Caution! Before starting, disconnect the instrument from the power source.

1. Take off the autoclave cover (see para. 9.2 “Removing the Autoclave’s Outer Covers”).

2. Disconnect the wires from the circuit breaker.

3. Remove the screws (1) connecting the circuit breaker to the panel.

4. Replace the circuit breaker with a new one.

5. Reconnect the electrical wires.

6. Reassemble the cover.

7. Turn on the autoclave and verify it operates correctly.

8. Move the circuit breaker’s lever to the “tripped” position and verify that the autoclave turns off.

Make sure that the correct circuit breaker is installed as specified

below:

Model 2540 - 1 circuit breaker - 20A

Model 3870 - 1 circuit breaker - 3 phase 20A.

Model 2540 EHS Model 3870 EHS

Circuit breaker

3ph 20A

Circuit breaker

20A

Screw c

Page 60

9.11 Replacing the water pump

The water pump supplies mineral - free water to the jacket of the

autoclave from the front compartment of the reservoir. This water is used by the steam generator to produce steam for sterilization.

The pump is protected from running dry and burning out, by the float

switch mounted in the lower part of the front reservoir compartment.

Caution! Before starting, disconnect the instrument from the power source

and ensure that there is no pressure in the autoclave’s chamber and jacket.

1. Take off the autoclave cover (see para. 9.2 “Removing the Autoclave’s Outer Covers”).

2. Disconnect the wires from the pump

3. Empty the water reservoir, by using the drain value on the front of the autoclave.

4. Disconnect the piping from the pump.

5. Remove the pump from the rubber shock absorbers. (If the rubber shock absorbers are damaged, replace them also).

6. Replace the damaged pump with a new pump.

7. Reconnect wiring and piping.

8. Turn on the autoclave and verify it operates correctly and none of the connections are leaking

9. Reassemble the cover.

No. Description 2540 3870

1 Rubber shock absorber SKR203-0006 SKR203-0006

1/8 elbow connection to Teflon 6x4mm tube



FIT100-0012

1/4 straight connection to Teflon 6x4mm tube

FIT100-0009



7 ULKA water pump PUM055-0010 PUM055-0010

Page 61

9.12 Pressure Switch

The Pressure Switch is designed as a safety device, limiting over-

pressure in the steam generator.

It is set to a pressure of 38 psig which is about 2 psi above the working

pressure of the generator.

The pressure switch is factory set and it should not be adjusted in the

field. Doing so will void the warranty.

To replace the pressure switch perform the following steps:

Caution! Before starting, disconnect the instrument from the power source

and ensure that there is no pressure in the chamber or jacket.

1. Remove the rear cover.

2. Disconnect the wires from the pressure switch.

3. Disconnect the pressure switch from the copper tube and replace it with a new one.

4. Reconnect the wires and reassemble the rear cover.

5. To verify that the autoclave operates as required perform a 274°F cycle.

Page 62

9.13 The Heaters

The autoclave contains internal submerged heaters, mounted at the

bottom back side of the jacket (see drawing below). Model 2540 has three (3) 1000W / 208V heaters. Model 3870 has six (6) 1000W / 208V heaters.

To replace heaters proceed as follows:

Caution!

Before starting, disconnect the instrument from the power source

and ensure that there is no pressure in the autoclave’s chamber and jacket.

1. Remove the rear cover plate by unscrewing the screws.

2. Discharge any steam pressure and drain the water from the jacket by gradually opening the drain valve (at the back of the unit). Wait until all the water has drained from the jacket. (see sec 9.17)

3. Disconnect the electrical leads for each heater from the heater terminal block.

4. Remove the heater by unscrewing and pulling it out from the jacket bushing.

5. Replace the heater with the new one, use Teflon on the thread to seal it. Tighten the heater to prevent leaking.

6. Connect the wires of the new heater to the terminal block.

7 Close the drain valve.

8. Connect the autoclave to the power source.

9. Turn the main switch to ON and check that the steam generator heats up correctly. Check also for any leaking by the heaters

10. Replace the rear panel

Page 63

9.14 The Dual Compartment Water Reservoir

9.14.1 Description

The dual compartment water reservoir is one unit with a wall

separating the two compartments.

The front compartment holds the mineral free water required

for the generation of steam in the jacket. Water enters at the top through a control valve from an external mineral-free water source. At the bottom is an outlet to the water pump which feeds water to the jacket. An additional outlet at the bottom connects the reservoir to a manual drain valve located on the front of the autoclave. A float switch mounted on the front wall of the reservoir controls the flow of water into the reservoir and a second float below it ensures that the water pump does not run if the compartment is empty

The second compartment supplies feed water to the vacuum

pump. Water enters at the top through a control valve from a public water source. An additional outlet at the bottom connects the reservoir to a manual drain valve located on the front of the autoclave. A float switch mounted on the rear wall of the reservoir controls the flow of water into the reservoir and a second float below it ensures that the vacuum pump does not run if the compartment is empty

The reservoir is also provided with an overflow drain. This is

a simple conduit mounted on the upper side of the rear wall, which directs excess water to the drain.

Also attached to the rear wall of the reservoir is a flexible

tubing connected to the aeration inlet of the vacuum pump.

Page 64

9.14.2 Replacement

It is possible to replace individual damaged components on

the reservoir. It is not necessary to replace the entire reservoir, however, if a complete replacement is needed follow the steps below.

Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the autoclave’s chamber and jacket.

1. Drain the reservoir from the two manual drains on the front of the autoclave.

2. Take off the autoclave cover (see para. 9.2 “Removing the Autoclave’s Outer Covers”).

3. Disconnect the wires to the float switches on the reservoir.

4. Disconnect any copper or plastic tubing going to the reservoir.

5. Disconnect any solenoid valves going to the reservoir.

6. Drill out the pop rivets holding the legs of the reservoir to the chassis.

7. Remove the reservoir from the autoclave.

8. Transfer any items still attached to the old reservoir, to the new reservoir. Replace any items that may be defective.

9. Place the new reservoir in position on the chassis and pop rivet the legs in place with a 3/16 pop rivet. As an alternative place a #10 machine screw from the bottom up through the chassis and leg and secure with a nut and washer on top.

10. Reconnect any wiring and tubing that had been disconnected earlier.

11. Turn on the autoclave and allow both compartments to fill with water. Verify that there are no leaks and that the autoclave is operating correctly

12. Reassemble the outer cover.

Page 65

9.15 The Water Sensing Electrodes

The two electrodes that control the water level of the jacket are located

in a stainless steel bottle, or housing, connected to the rear of the autoclave. The housing is connected to the jacket by upper and lower copper tubes, which allows the jacket water to flow in and out of the housing. The water level in the housing will be identical to the water level in the jacket.

The High Electrode, which is physically higher when looking at the top

of the housing, determines the operational water level in the jacket.

The Low Electrode, which is physically lower when looking at the top

of the housing, protects the heaters by switching them off when there is too little water in the jacket.

To clean or replace the electrodes proceed as follows (refer to drawings

on the next page:

Caution! Before starting, ensure the electric cord is disconnected and there is no pressure in the chamber or jacket.

1. Take off the autoclave cover (see para. 9.2 “Removing the Autoclave’s Outer Covers”).

2. Discharge the steam pressure and drain the water from the jacket by opening the water drain valve located at the rear of the autoclave. (See sec 9.17)

3. Remove the electrical connections from the terminals of the electrodes. Mark the wires for each electrode to avoid miss wiring when reinstalling the electrodes.

4. Unscrew the locking nut and remove the electrode from the top of the housing.

5. Replace the electrode with a new one or reinstall the same electrode after cleaning.

5.1 To clean the electrode use a damp cloth or sponge. A mild

soapy solution may be used, rinse thoroughly. DO NOT use any harsh chemicals

5.2 When positioning the new electrode, make sure to position the

high electrode tip so it is in line with the center of the chamber. Position the low electrode so that it’s tip is approximately 1”, but not les than 1”, lower than the high electrode tip.

6. Tighten the locking nut to prevent any steam or water from leaking out.

7. Reconnect the electrical wires to the electrode terminals. Making sure to connect the correct wire to the proper electrode. If these connections are reversed, the steam generator will not heat.

8. Close the drain valve and turn the autoclave on. The unit will automatically fill with water. Observe that the unit is heating. Wait for the unit to reach 30 psig, then check for leaks around the locking nuts.

9. Reassemble the cover.

Page 66

Page 67

9.16 The Vacuum Pump

9.16.1 Description

To produce the vacuum needed in the prevacuum and drying

stages, the autoclave is equipped with a liquid ring pump. This pump is suitable for continuous operation, and achieving a high vacuum necessary for proper operation. To produce the needed vacuum the pump draws water from the reserve in the rear compartment of the water reservoir. There is a minimum Water Quality requirement for the pump to ensure trouble free operation (ref. par. 3.8.2.)

A float switch is mounted to the lower rear wall of the

reservoir to prevent the pump from running when there is no water in the reservoir.

9.16.2 Replacing the vacuum pump

Caution! Before starting, disconnect the instrument from the power

source and ensure that there is no pressure in the autoclave’s chamber and jacket.

For location of inlets and outlet of the pump, refer to

drawing on the next page

1. Take off the autoclave cover (see para. 9.2 “Removing the Outer Covers of the Autoclave”).

2. Close the external Feed Water Supply valve going to the back of the autoclave. Count the number of turns and mark it down for use at the end of this procedure.

3. Drain the water from the reservoir, using the manual drain on the front of the machine.

4. Disconnect the electrical wires from the pump. Note the location of the wires for later use.

5. Disconnect any plumbing. Note the location of the plumbing connections for later use.

6. Replace the pump.

7. Reconnect the wires and piping previously removed.

Caution

Ensure that the protective earth ground of the

vacuum pump is reconnected before power is turned on.

8. Open the external Feed Water Supply valve going to the back of the autoclave. Make sure to open it the same number of turns as had been counted earlier. Allow the rear compartment of the reservoir to fill.

9. Turn on the power and observe that the reservoir fills properly. Run a sterilization cycle to verify that the pump performs correctly, without leaking.

10. Reassemble the cover.

Page 68

Page 69

9.17 Draining the Jacket

Caution Before starting, ensure that the electric cord is disconnected and

there is no pressure in the chamber or jacket.

1. Turn off the main switch.

2. Remove the rear cover.

3. Turn the valve handle (1) 1/4 turn and the jacket will begin to drain.

4. Close the valve, and re-assemble the rear cover

Page 70

9.18 Replacement of the Door Cover

Caution: Before starting, be sure that the electric cord is disconnected from the

power source and that there is no pressure in the autoclave chamber.

1. Unscrew the four screws attaching the door cover and remove the door cover. Note that the screw that activates the door microswitch includes two washers and a spring, be careful not to lose them.

2. Position the new cover and screw in three screws (2).

3. Assemble and install the door microswitch activator. Insert screw (1) through washers (3) and spring (4) and screw into the door until dimension A is approximately 15 mm.

4. Before proceeding, make certain that the door gasket is in good condition. Perform final adjustment of the door microswitch activator as follows:

4.1 Press the microswitch and listen to hear it click. The clicking

sound indicates that the microswitch has been activated.

4.2 Close the door until the closing device feels tight, also verifying

that the microswitch click was heard.

4.3 If the microswitch does not click then unscrew the screw (1) one

turn counter- clockwise and check again. Repeat until the microswitch click is heard.

4.4 Turn the main power back on.

4.5 Close the door until the closing device feels tight, but do not over

tighten. Make sure a click is heard.

4.6 Select a steam cycle and run the autoclave. Check that there is no

steam or pressure leak around the door.

4.6.1 If there is a leak then tighten the door slightly.

4.6.2 If the door-open indicator sounds and the door LED lights then repeat step 4.3

No. Description Model

Cat. No.

2 Screw Both models BOL191-0140

2540 POL066-0002

5 Door cover

3870 POL065-0003

Spacer kit 1 + 3 + 4 Both models CT312036

Page 71

9.19 Replacing the Closing Device

Caution: Before starting, verify that there is no pressure in the autoclave

chamber.

1. Remove the “C” clip (9) from the bottom of the door locking pin (6). Newer models will have a cotter pin.

2. Remove the locking pin (6) by pulling it up out of its position.

3. Remove the closing device assembly. Be careful not to lose the two Teflon disks (10) resting on the top and bottom of the lock housing axe (5).

4. Position the new closing device on the lock housing axe (5), making sure that the Teflon disks (10) are in between the lock housing axe (5) and the screw housing (3).

5. Insert the pin (6).

6. Replace the “C” clip or cotter pin (9).

CLOSING DEVICE

No. Description No. Description

1 Bushing 6 Door locking device pin 2 Door tightening bolt assembly 7 Bakelite handle 3 Locking screw housing 8 Closing bridge “c” clip 4 Locking base 9 Cotter pin 5 Locking housing axe 10 Teflon disk

Page 72

9.20 PT100 Temperature Sensor Replacement

The temperature sensor is located below the chamber at the front. It is

mounted in a fitting (1) that is part of the chamber drain system (see picture below).

Caution! Before starting, disconnect the instrument from the power source

and ensure that there is no pressure in the autoclave’s chamber and jacket.

1. Take off the autoclave cover (see para. 9.2 “Removing the Outer Covers of the Autoclave”).

2. Unscrew the nut (3) attaching the sensor (2) to the fitting (1).

3. Remove the sensor from the fitting.

4. Disconnect the sensor’s wire (4) from the electronic box and remove the sensor from the autoclave.

5. Install a new sensor. Ensure that the tip of the sensor is positioned at, but not past the center of the nipple attached to the chamber. Any other positioning will result in an inaccurate reading.

6. Connect the sensor’s wire to the electronic box.

7. Reassemble the cover.

8. After any replacement or repositioning recalibrating the machine is necessary (see sec 5)

Page 73

10 TROUBLESHOOTING

10.1 Preliminary Check

Before performing any troubleshooting operation and before removing

the autoclave’s cover, check the following:

1. Electrical power: Verify that:

a. Power supply is 1ph/208 VAC for model

2540 and 3ph/208 VAC for model 3870.

b. It has an earth wire.

2. Mineral free water: ½” connection. Water pressure, after the pressure reducer (as indicated on the pressure reducer’s gauge) must be 7-30 psi.

3. City water: ½” connection. Water pressure, after the pressure reducer (as indicated on the pressure reducer’s gauge) must be 15-58 psi.

4. Drain: The drain tube must be connected directly to the sewage. It must be straight and not elevated to any degree. The drain opening should be within 1 foot of the rear of the unit and no higher than 16” above the floor.

In order to locate any malfunctioning component perform the “in-out

test” this test enables the technician to activate most of the components and test the analog and digital inputs, This enables the technician to verify whether the problem is caused by an end item, by the control system or by any other reason.

Before any operation or test on the autoclave perform a visual check

for loose parts or for signs of over-heating and burnt components.

10.1.1 Manual Valves

There are four (4) manual control valves (see piping diagram)

and the technician must verify that they are open as instructed below.

There is one manual control valve on the incoming mineral

free water line.

There are two valves on the feed water line and there is one

valve that acts as a bypass to the steam trap.

The three incoming waterline valves are used to regulate flow

and should be opened 2 –3 full turns. One controls feed water flow to the vacuum pump reservoir, one controls flow to the mineral free water reservoir and one controls flow of feed water for cooling the exhaust drain. (Since the majority of drains are made of PVC pipe the exhaust temp needs to remain below 140ºF. the cooling water valve is used to maintain drain temperatures well below 140ºF.

The steam trap bypass valve is used to control steam escaping

from the chamber and should be open ¼ - ½ turn. Restricting the flow of steam too much or too little will result in a system failure.

To set or check the valves, close them fully make an indicator

mark if one is not present and open the proper number of turns.

Page 74

Corrections

1.1.1 Fix leakage.

1.1.2 Replaces the faulty heating

elements.

1.1.3 Replace the faulty pressure switch.

1.1.4.1 Reset the cut-off

thermostat. If it does not

help – replace it.

1.1.5.1 Reset the cut-off

thermostat. If it does not

help – replace it.

1.1.5.2 Fix connection.

1.1.5.3 Replace faulty contactor.

1.1.6.1 Clean the contaminated

electrode.

1.1.6.2 Replace faulty electrode.

1.1.6.3 Fix electrode electrical

connections.

1.1.6.4.1 Clean clogged

piping.

1.1.6.4.2 Replace water

pump.

1.1.6.4.3 Replace non-

return valve.

Possible cause check-up and tests

1.1 Low temperature and low pressure.

1.1.1 Check leakage from the chamber or from

the jacket.

1.1.2 Faulty heating element.

1.1.3 Faulty pressure switch.

1.1.4 On model 2540 only:

1.1.4.1 Cut-off thermostat disconnects

the heating element.

1.1.5 On model 3870 only:

1.1.5.1 Cut-off thermostat disconnects

command to the contactor that

disconnects the heating element.

1.1.5.2 The contactor is disconnected.

1.1.5.3 Faulty contactor.

1.1.6 Lower water level electrode does not sense

water. Possible cause:

1.1.6.1 Contaminated electrode.

1.1.6.2 Faulty electrode.

1.1.6.3 Electrode disconnected.

1.1.6.4 Low or no water inlet and water

pump operates too often.

1.1.6.4.1 Water inlet pipe to the

chamber is clogged.

1.1.6.4.2 Faulty water pump.

1.1.6.4.3 Water-inlet Non-

return valve is stuck.

10. TROUBLESHOOTING (cont.)

10.2 Preliminary Troubleshooting

Symptom

1. “Low temp” is displayed

Page 75

Corrections

1.2.1 Clean or replace clogged steam trap.

1.2.2 Clean clogged pipe.

1.2.3 Close needle valve completely and

open half a turn.

1.2.4 See item 10.4.31.

1.3 Calibrate temperature and/or pressure.

2.1.1.1 Replace clogged steam trap.

2.1.1.2 Close needle valve

completely and open half a

turn.

2.1.1.3 Clean clogged pipes.

2.1.14 See item 10.4.31.

2.2.1.1 Replace faulty relay.

2.2.1.1 Replace faulty board.

Possible cause check-up and tests

1.2. High pressure and low temperature Water is not

discharged from the chamber. Possible cause:

1.2.1 Steam trap clogged.

1.2.2 Exhaust drain pipe clogged.

1.2.3 Steam trap by-pass (needle valve) is too

closed.

1.2.4 Slow exhaust valve (74) does not open

1.3 Temperature and/or pressure are not calibrated.

2.1 Pressure is high and temperature is low.

2.1.1 Slow exhaust or drain lines are clogged

due to:

2.1.1.1 Clogged steam trap.

2.1.1.2 Needle valve, of the slow exh by-

pass, is closed.

2.1.1.3 Outlet or slow exh to drain pipes

are clogged.

2.1.1.4 Slow exhaust valve (74) is stuck

closed.

2.2 Pressure and temperature are high.

2.2.1 Heating elements operate constantly due

to:

2.2.1.1 Faulty Solid State Relay (SSR)

(located in the electronic box).

2.2.1.2 Faulty digital board DIG-T2

(located in the electronic box).

2.2.1.1 Faulty analogue board ANL-T2

(located in the electronic box).

10. TROUBLESHOOTING (cont.)

10.2 Preliminary Troubleshooting (cont.)

Symptom

1. “Low temp” is displayed

(cont.)

2. “High press” is displayed.

Page 76

Corrections

3.1.1 Fix leakage from chamber and

jacket.

3.1.2 Replace the faulty heating element.

3.1.3 Replace the pressure switch.

3.1.4.1 Reset the cut-off

thermostat. If it does not

help – replace it.

3.1.5.1 Reset the cut-off

thermostat. If it does not

help – replace it.

3.1.5.2 Fix connection.

3.1.5.3 Replace faulty contactor.

3.1.6.1 Clean the contaminated

electrode.

3.1.6.2 Replace faulty electrode.

3.1.6.3 Fix electrode electrical

connections.

3.1.6.4.1 Clean clogged

piping.

3.1.6.4.2 Replace water

pump.

3.1.6.4.3 Replace non-

return valve.

3.1.7 Replace faulty water pump.

3.1.8 Clean clogged pipe and/or filter.

Possible cause check-up and tests

3.1 Pressure and temperature are low.

3.1.1 Leakage from the chamber or from the

jacket.

3.1.2 Faulty heating element.

3.1.3 Pressure switch faulty or adjusted to low

pressure.

3.1.4 On model 2540 only:

3.1.4.1 Cut-off thermostat disconnects

the heating element.

3.1.5 On model 3870 only:

3.1.5.1 Cut-off thermostat disconnects

command to the contactor that

disconnects the heating element.

3.1.5.2 The contactor is disconnected.

3.1.5.3 Faulty contactor.

3.1.6 Lower water level electrode does not sense

water. Possible cause:

3.1.6.1 Contaminated electrode.

3.1.6.2 Faulty electrode.

3.1.6.3 Electrode disconnected.

3.1.6.4 Low or no water inlet and water

pump operates too often.

3.1.6.4.1 Water inlet pipe to the

chamber is clogged.

3.1.6.4.2 Faulty water pump.

3.1.6.4.3 Non-return valve on

water inlet pipe is

stuck.

3.1.7 Faulty water pump.

3.1.8 Water inlet pipe and/or filter are clogged.

10. TROUBLESHOOTING (cont.)

10.2 Preliminary Troubleshooting (cont.)

Symptom

3. “Low press” is displayed

Page 77

Corrections

3.2.1 Fix leakage.

3.2.2 Calibrate pressure and/or

temperature (as appropriate).

3.2.3 See item 10.4.8.

3.2.4 See item 10.4.3.

3.2.5 See item 10.4.35.

3.2.6 See item 10.4.30.

3.2.7 See item 10.4.29.

4.1.1 Replace faulty steam trap.

4.1.2 Replace faulty needle valve.

4.1.3 Replace faulty temperature sensor.

4.1.4 Replace faulty pressure sensor.

4.1.5 Calibrate temperature and/or

pressure as appropriate.

4.1.6 Fix leakage.

4.1.7 Replace faulty steam trap.

4.1.8 Close needle valve completely and

open half

a turn.

4.2.1.1 Replace faulty Solid State

Relay (SSR).

4.2.1.2 Replace faulty board.

4.2.1.3 Replace faulty board.

Possible cause check-up and tests

3.2. Low pressure and high temperature.

3.2.1 Exhaust or slow exhaust outlets are leaking.

3.2.2 Temperature or pressure are not calibrated.

3.2.3 Air inlet valve (43) is stuck open.

3.2.4 Vacuum valve (52) is stuck open.

3.2.5 Fast exhaust valve (73) is stuck open.

3.2.6 Slow exhaust valve (74) is stuck open.

3.2.7 Steam valve (93) is stuck open.

4.1 High temperature and low pressure.

4.1.1 Steam trap is leaking.

4.1.2 Needle valve of the steam trap is leaking.

4.1.3 Temperature sensor (PT100) is faulty.

4.1.4 Pressure sensor is faulty.

4.1.5 Temperature or pressure are not calibrated.

4.1.6 Exhaust line, chamber or jacket are leaking.

4.17 Faulty steam trap.

4.1.8 needle valve open

4.2 Pressure and temperature are high.

4.2.1 Heating elements operate constantly due to:

4.2.1.1 Faulty Solid State Relay (SSR)

(located in the electronic box).

4.2.1.2 Faulty digital board DIG-T2

(located in the electronic box).

4.2.1.3 Faulty analogue board ANL-T2

(located in the electronic box).

10. TROUBLESHOOTING (cont.)

10.2 Preliminary Troubleshooting (cont.)

Symptom

3. “Low press” is displayed

(cont.)

4. “High temp” is displayed.

Page 78

Corrections

5.1 Fix leakage.

5.2 Replace heating element.

5.3 Replace faulty pressure switch.

5.4 Replace faulty cut-off thermostat.

5.5.1 Replace faulty electrode.

5.5.2 Replace faulty water pump.

5.5.3 Clean clogged pipes.

5.5.4 See item 10.4.8.

5.5.5 See item 10.4.3.

5.5.6 See item 10.4.35.

5.5.7 See item 10.4.30.

5.5.8 See item 10.4.29

6.1 Fix mineral free water supply..

6.2 Fix pressure of mineral free water source.

6.3 Clean clogged inlet.

6.4 Replace stuck valve.

6.5 Replace faulty float.

Possible cause check-up and tests

5.1 piping leaking.

5.2 Faulty heating elements.

5.3 Faulty pressure switch.

5.4 Faulty cut-off thermostat (on model 3870).

5.5 Lower electrode does not sense water.

5.5.1 Faulty electrode.

5.5.2 Faulty water pump.

5.5.3 Water inlet pipe to the jacket is clogged.

5.5.4 Air inlet valve (43) is stuck open.

5.5.5 Vacuum valve (52) is stuck open.

5.5.6 Fast exhaust valve (73) is stuck open.

5.5.7 Slow exhaust valve (74) is stuck open.

5.5.8 Steam valve (93) is stuck open.

6.1 Faulty mineral free water supply.

6.2 Pressure of mineral free water source is low.

6.3 Mineral free water inlet line is clogged.

6.4 Mineral free water inlet valve (21) is stuck.

6.5 Float in mineral free water reservoir is faulty.

10. TROUBLESHOOTING (cont.)

10.2 Preliminary Troubleshooting (cont.)

Symptom

5. “Low heat“ is displayed.

6. “Add water” is displayed.

Page 79

Corrections

7.1 fix leakage.

7.2 replace faulty vacuum pump/

7.3 fix leaking piping.

7.4 replace stuck non-return valve

7.5.1 Replace faulty coil and/or plunger.

7.5.2 Fix disconnection.

7.5.3 Replace faulty board.

7.5.4 Replace faulty board.

7.5.5 See item 10.4.8.

7.5.6 See item 10.4.35.

7.5.7 See item 10.4.30.

7.5.8 See item 10.4.29

Possible cause check-up and tests

7.1 Chamber is leaking.

7.2 Faulty vacuum pump.

7.3 Vacuum piping is leaking.

7.4 Non-return valve is stuck.

7.5 Vacuum valve (52) does not open during vacuum

stage due to:

7.5.1 Faulty coil or plunger.

7.5.2 Pump disconnected.

7.5.3 Faulty digital board DIG-T2 (located in

the electronic box).

7.5.4 Faulty analogue board ANL-T2 (located

in the electronic box).

7.5.5 Air inlet valve (43) leaks or is stuck open.

7.5.6 Fast exhaust valve (73) leaks or is stuck

open.

7.5.7 Slow exhaust valve (74) leaks or is stuck

open.

7.5.8 Steam valve (93) leaks or is stuck open.

10. TROUBLESHOOTING (cont.)

10.2 Preliminary Troubleshooting (cont.)

Symptom

7. “Low vacuum” is

displayed.

Page 80

Corrections

1.1 Replace damaged cord or repair faulty

connections.

1.2 Reset the circuit breaker and observe if it

trips again, if so check for a short circuit.

1.3

 Replace the On/Off Rocker switch.

 Have the facilities electrical circuit

upgraded.

Possible cause check-up and tests

1.1 Check that the main power is turned on,

the power cord and the connections to the

circuit breaker.

1.2 Check the circuit breaker. If it is tripped,

there is possibly a short-circuit.

1.3 Check the AC voltages.

— The input voltage comes from the

circuit breaker to the On/Off switch

then to the AC-T1 board – See the

Electrical Wiring Diagram. The voltage

must be 208 VAC.

— With a multimeter check from pin 3 at

the AC-INPUT connector (JP3), on the

AC-T1 board, to pins 1 and 2.

— Turn on the power. The reading must

be the same as the voltage coming from

the wall outlet for the machine. If not:

 The On/Off Rocker switch contacts

may be loose.

 The electrical circuit supplying the unit

may not be able to handle the load.

10. TROUBLESHOOTING

10.3 Pre-process malfunction

If the malfunction is possibly caused by the electronic system, the following should be

performed prior to any corrective action:

Clean the grid

under the fan with compressed air. This should be done from inside so debris will be blown outwards.

Clean the entire electronic box with compressed air. (dirt can be conductive and possibly causing a short in the circuit)

Symptom

1. No response when the

system is turned on

Page 81

Corrections

1.4

— If the DC voltages at the power supply

connector are incorrect or missing, with

the load disconnected, then replace the

power supply.

— Replace faulty cables.

— Fix damaged connectors

— If voltages are missing or incorrect then

replace the ANL-T2 board

Possible cause check-up and tests

— Check for AC power at the JP2

connector on the AC-T1 board

— Check for power at the AC input to the

power supply

1.4 Check the DC voltages supplied to the

system.

— Connect the Test Point board to the

JP7 connector on the ANL-T2 board.

— Connect the negative probe of a

multimeter to TP1 on the test board.

— With the positive probe check TP2 for

+5V DC, an acceptable range is

4.9 – 5.3V

— With the positive probe check TP3 for

+12V DC, an acceptable range is

10.8 – 12.5V

— If either voltage is incorrect or missing,

then remove the output connector from

the power supply and recheck at the

power supply connector.

— If the voltages are with in range then

reconnect the output connector and

proceed

— Turn off the power and disconnect all

connectors except JP8 from the

ANL-T2 board. Inspect all cables for

loose connectors and all connectors for

bent pins.

10. TROUBLESHOOTING (cont.)

10.3 Pre-process malfunction (cont.)

Symptom

1. (cont.)

Page 82

Corrections

— Repair or replace the

faulty item.

1.5

— Tighten loose screws.

— Reconnect grounding

cable.

Possible cause check-up and tests

— Turn the power back on and check for 5V

and 12V on the Test Point board, if

voltages are okay, then one connector at a

time reconnect the connector and test the

voltage. Each time turning the power off

before reconnecting.

— If a cable or connector causes a problem,

but the cable or connector are, good then

proceed down the line to the device

attached to the other end of the cable or

connector and continue with the previous

step. The problem could

be with any one of the external devices

connected to the system (valves, sensors,

etc.) or another electronic board.

1.5 Check the grounding

— Connect the negative probe of the

multimeter to TP1 on the Test Point board.

— Using the positive probe check the voltage

at various grounding points on the

autoclave, on the ANL-T2 and DIG-

T2 boards, on the enclosure of the electric

box and the main grounding screw of the

machine.

10. TROUBLESHOOTING (cont.)

10.3 Pre-process malfunction (cont.)

Symptom

1. (cont.)

Page 83

Corrections

2.1 Replace DIG-T2 board

3.1 Replace DIG-T2 board.

4.1 Replace the keyboard.

4.2 Replace the DIG-T2 board.

5.1 Check that the Atmos.Press parameter

(sec 8.2.17) is set to the correct

atmospheric pressure.

5.2 The sensor is faulty. Replace sensor.

Possible cause check-up and tests

— The voltage reading must be less than

5mV. A higher voltage may indicate

that the ANL-T2 board fastening

screws are loose or that the power

supply grounding cable is loose.

2.1 If the other functions are OK, the display

is probably damaged.

3.1 DIG-T2 board is faulty.

4.1 Keyboard is faulty.

4.2 DIG-T2 board is faulty.

5.1 Check if the displayed value is near the

atmospheric pressure.

5.2 If after setting the Atmos.Press parameter

the displayed value is significantly

different from the atmospheric pressure

there is a problem with the pressure

sensor.

10. TROUBLESHOOTING (cont.)

10.3 Pre-process malfunction (cont.)

Symptom

1. (cont.)

2. System is on and display is

not lit.

3. System on and erroneous or

fragmented digits.

4. No response from one of

the keys.

5. The displayed readout for

the atmospheric pressure,

when the door of the

chamber is open, does not

conform to the actual

absolute pressure.

Page 84

Corrections

6.1 See symptom 20 in para. 10.4.

7.1 make sure water pump is working. Make

sure electrode wires are connected

Possible cause check-up and tests

6.1 Incorrect reading of the reservoir float

switch position.

7.1 Check that the electrodes are sensing

water in the jacket

10. TROUBLESHOOTING (cont.)

10.3 Pre-process malfunction (cont.)

Symptom

6. Pressing the START key

does not start the process

and the error message

ADD WATER is displayed

despite the water reservoir

being full.

7. Unit will not heat but

display is on (except during

vacuum test).

Page 85

Corrections

1.1 Close the door more tightly or readjust

the door switch to activate earlier.

2.1 Check the valve as per para 10.4 sections

35 & 36. Replace either the fast exhaust

valve (73), no return valve or clean the

drain line as needed.

2.2 Clean clogged strainer.

Possible cause check-up and tests

1.1 As the pressure in the chamber rises

during the heat up stage it presses

outward on the door. This can cause the

door switch to be released and cause the

system to think the door is opened.

2.1 Fast exhaust valve (73) is faulty or the

discharge line from the chamber to drain

is clogged or the no return valve is faulty.

2.2 Strainer is clogged

10. TROUBLESHOOTING (cont.)

10.4 In Process Malfunction

Symptom

1. Message DOOR UNLOCK

is displayed during the

heating stage, although the

door is closed.

2. The fast exhaust

operation is too slow

Page 86

Corrections

3.1 Replace the DIG-T2 board.

3.2 Fix the connections.

3.3 Disassemble the valve and check that the

plunger is free to move and that the seat

is clean and free from debris.

3.4 Replace the ANL-T2 board.

Possible cause check-up and tests

The problem may be a mechanical failure of the

valve, the valve driver located on the ANL-T2

board or the control circuit on the

DIG-T2 board.

3.1 Check TP8. If the voltage is higher than

4V and the valve is open, then the DIG-

T2 board is faulty.

If the voltage at TP8 is <1VDC and the

valve is open, the problem is not the

DIG-T2, but some other element of the

system.

3.2 Check the connection between the

connector JP10 - 4 and the valve for a

ground short.

3.3 Remove the cover protecting the

terminals of the coil and check the

voltage across the coil when the solenoid

is connected. If the coil voltage is less

than 2V and the valve is open, there is a

mechanical problem.

3.4 If the voltage across the coil is higher

than 10VDC, then the ANL-T2 board is

faulty.

10. TROUBLESHOOTING (cont.)

10.4 In Process Malfunction (cont.)

Symptom

3. Vacuum valve (52) is

always open (3870 has 2

valves #52 working

together).

Page 87

Corrections

4.1 Replace the DIG-T2 board.

4.2 Fix the connections.

4.3 Disassemble the valve and check that the

plunger is free to move and that the seat

is clean and free from debris.

4.4 Replace the coil

Possible cause check-up and tests

The problem may be caused by the mechanical

part of the valve or the driver located on the

ANL-T2 board or the control circuit on the DIG-

T2 board.

4.1 Check TP8. If the voltage is constantly

<1VDC, while the valve is supposed to

be open, then the problem is on DIG-T2

board.

4.2 Check the connection between connector

JP10 - 4 and the valve for an open circuit.

4.3 Check the coil input voltage with the

solenoid connected to the valve. If the

voltage is higher than 10VDC and the

valve does not open, then the solenoid or

the mechanical part of the valve are

faulty.

4.4 Take an ohm reading across the solenoid

coil, a 10W coil is 14-15 ohms and a

12W coil is 9-10 ohms. An incorrect ohm

reading means the coil is faulty. Check

from the coil terminal to the ground

terminal, any reading other than 0VDC

means the coil is faulty.

10. TROUBLESHOOTING (cont.)

10.4 In Process Malfunction (cont.)

Symptom

4. Vacuum valve (52) is

always closed (3870 has 2

valves #52 working

together).

Page 88

Corrections

5.1 Replace the DIG-T2 board.

5.2 Fix the connections.

5.3 Disassemble the valve and check that the

plunger is free to move and that the seat

is clean and free from debris.

5.4 Replace the ANL-T2 board.

Possible cause check-up and tests

The problem may be a mechanical failure of the

valve, the valve driver located on the ANL-T2

board or the control circuit on the DIG-T2 board.

5.1 Check TP9. If the voltage is higher than

4V and the valve is open, then the DIG-

T2 board is faulty. If the voltage at TP9

is <1VDC and the valve is open, the

problem is not the DIG-T2, but some

other element of the system.

5.2 Check the connection between the

connector JP10 - 5 and the valve for a

ground short.

5.3 Remove the cover protecting the

terminals of the coil and check the

voltage across the coil when the solenoid

is connected. If the coil voltage is less

than 2V and the valve is open, there is a

mechanical problem.

5.4 If the voltage across the coil is higher

than 10VDC, then the ANL-T2 board is

faulty.

10. TROUBLESHOOTING (cont.)

10.4 In Process Malfunction (cont.)

Symptom

5. Water inlet valve (21) to

mineral free reservoir is

always open

Page 89

6.1 Replace the DIG-T2 board.

6.2 Fix the connections.

6.3 Disassemble the valve and check that the

plunger is free to move and that the seat

is clean and free from debris.

6.4 Replace the coil.

Corrections

The problem may be caused by the mechanical

part of the valve or the driver located on the

ANL-T2 board or the control circuit on the DIG-

T2 board.

6.1 Check TP9. If the voltage is constantly

<1VDC, while the valve is supposed to

be open, then the problem is on DIG-T2

board.

6.2 Check the connection between connector

JP10 - 5 and the valve for an open circuit.

6.3 Check the coil input voltage with the

solenoid connected to the valve. If the

voltage is higher than 10VDC and the

valve does not open, then the solenoid or

the mechanical part of the valve are

faulty.

6.4 Take an ohm reading across the solenoid

coil, a 10W coil is 14-15 ohms and a

12W coil is 9-10 ohms. An incorrect ohm

reading means the coil is faulty. Check

from the coil terminal to the ground

terminal, any reading other than 0VDC

means the coil is faulty.

Possible cause check-up and tests

6. Water inlet valve (21) to

mineral free reservoir is

always closed

Symptom

10. TROUBLESHOOTING (cont.)

10.4 In Process Malfunction (cont.)

Page 90

Corrections

7.1 Replace the DIG-T2 board.

7.2 Fix the connections.

7.3 Disassemble the valve and check that the

plunger is free to move and that the seat

is clean and free from debris.

7.4 Replace the coil.

Possible cause check-up and tests

The problem may be caused by the mechanical

part of the valve or the driver located on the

ANL-T2 board or the control circuit on the DIG-

T2 board.

7.1 Check TP7. If the voltage is constantly

<1VDC, while the valve is supposed to

be open, then the problem is on DIG-T2

board.

7.2 Check the connection between connector

JP10 - 3 and the valve.

7.3 Check the coil input voltage with the

solenoid connected to the valve. If the

voltage is higher than 10VDC and the

valve does not open, then the solenoid or

the mechanical part of the valve are

faulty.

7.4 Take an ohm reading across the solenoid

coil, a 10W coil is 14-15 ohms and a

12W coil is 9-10 ohms. An incorrect ohm

reading means the coil is faulty. Check

from the coil terminal to the ground

terminal, any reading other than 0VDC

means the coil is faulty.

10. TROUBLESHOOTING (cont.)

10.4 In Process Malfunction (cont.)

Symptom

7. Air valve (43) is always

closed.

Page 91

Corrections

8.1 Replace the DIG-T2 board.

8.2 Fix the connections.

8.3 Disassemble the valve and check that the

plunger is free to move and that the seat

is clean and free from debris.

8.4 Replace the ANL-T2 board.

Possible cause check-up and tests

The problem may be a mechanical failure of

the valve, the valve driver located on the ANL-

T2 board or the control circuit on the

DIG-T2 board.

8.1 Check TP7. If the voltage is higher than

4V and the valve is open, then the DIG-

T2 board is faulty.

If the voltage at TP7 is <1VDC and the

valve is open, the problem is not the

DIG-T2, but some other element of the

system.

8.2 Check the connection between the

connector JP10 - 3 and the valve for a

ground short.

8.3 Remove the cover protecting the

terminals of the coil and check the

voltage across the coil when the solenoid

is connected. If the coil voltage is less

than 2V and the valve is open, there is a

mechanical problem.

8.4 If the voltage across the coil is higher

than 10VDC, then the ANL-T2 board is

faulty.

10. TROUBLESHOOTING (cont.)

10.4 In Process Malfunction (cont.)

Symptom

8. Air valve (43) is always

open.

Page 92

Corrections

9.1 Replace DIG-T2 board.

9.2 Replace ANL-T2 board.

9.3 Test the SSR (see symptom 34)

10.1 If an incorrect voltage is seen then check

across the input terminals of the circuit

breaker and the output from the wall outle

10.2 If correct voltages are seen across all

terminals on the block then the problem is

with the heater elements. Disconnect the

heaters and take an ohm reading across the

heater. A proper reading for each element

would be 43 ohms for a 208 volt heater or

53 ohms for a 230 volt heater (+/- 10%).

Possible cause check-up and tests

This can be the result of a failure of the control

circuit on the DIG-T2 board or of the heating

elements driver on the ANL-T2 board or the Solid

State Relay.

9.1 Check TP4. if the voltage is higher than

4VDC the problem is on DIG-T2 board.

9.2 If the voltage at TP4 is <1VDC the

problem could be either the ANL-T2 or

the SSR. Turn power off and remove the

wire from terminal 4 of the SSR. Turn

the power back on. If the heaters remain

off then the problem is with the ANL-T2.

9.3 If the heaters come back on the problem

is with the SSR.

10.1 Check for the proper voltage across the

output terminals of the circuit breaker.

10.2 With TP4 at or above 4 VDC check for

correct voltage across the terminals of the

heater element terminal block located

next to the main circuit breaker. The

2540 has two terminals and the 3870 has

three terminals. The correct voltage

should be seen across all combinations of

any two terminals.

10. TROUBLESHOOTING (cont.)

10.4 In Process Malfunction (cont.)

Symptom

9. Heating elements are

permanently activated.

10. Heating elements will not

heat the jacket, but the

display is on.

Page 93

Corrections

10.3.1 Reset or replace the Cut-Off thermostat.

10.3.2 make sure the water pump is working.

Make sure that the wires are connected to

the electrodes. Check electrode assembly

sec 9.16.

10.3.3 Replace the DIG-T2 board

10.3.4 If the Pressure Switch is open replace it

(DO NOT attempt to adjust this device).

10.3.5 Check the SSR (see symptom 34).

10.3.6 If all the preceding tests are good then

replace the ANL-T2 board

10.4.1 Reset the cut-off thermostat. If it does not

help – replace it.

10.5.1 Reset the cut-off thermostat. If it does

not

10.5.2 Fix connection.

10.5.3 Replace faulty contactor.

11.1 Replace the DIG-T2 board.

11.2 With the JP1 removed if the pump

continues to run then replace the AC-T1

board. If the pump stops then replace the

ANL-T2

Possible cause check-up and tests

10.3 If no voltage is seen at the terminal block

then check if the Cut-Off thermostat is

open. If the voltage at TP4 is always

<1VDC then check if the electrodes are

sensing water in the jacket. If they are,

then the problem is the DIG-T2 board.

If the voltage at TP4 is higher than

4VDC the problem could be with either

the ANL-T2, the SSR, the pressure

switch or the Cut-Off thermostat.

10.4 On model 2540 only:

10.4.1 Cut-off thermostat disconnects the

heating element.

10.5 On model 3870 only:

10.5.1 Cut-off thermostat disconnects

command to the contactor that

disconnects the heating element.

10.5.2 The contactor is disconnected.

10.5.3 Faulty contactor.

The problem may be a failure of the control

circuit on the DIG-T2 board or the driver on the

AC-T1 board.

11.1 Check TP5. If the voltage is higher than

4V then the DIG-T2 board is faulty.

11.2 If the voltage at TP5 is <1VDC the

problem is either the AC-T1 board or the

ANL-T2 board. Turn off the power and

remove the JP1 connector on the AC-T1,

turn the power back on.

10. TROUBLESHOOTING (cont.)

10.4 In Process Malfunction (cont.)

Symptom

10. Heating elements will not

heat the jacket, but the

display is on. (cont)

11. The vacuum pump works

continuously

Page 94

Corrections

12.1 Correct any problem with the tap water

inlet

12.2 Replace faulty float switch.

12.3 Replace blown fuse.

12.4 If the pump will not rotate feely then

replace the pump

12.5 Replace the DIG-T2 board

12.6 If approximately 120VAC is present then

the pump is faulty and should be

replaced. If no voltage is present then

replaced the AC-T1 board.

12.7 Clear any clog and / or replace the filter

or valve. Once the pump has cooled it

will start working again.

Possible cause check-up and tests

12.1 Check that the vacuum pump reservoir is

full and tap water will flow in freely.

12.2 The lower float in the vacuum pump

reservoir may be faulty, stopping the

pump.

12.3 Check the fuse at the rear of the unit.

12.4 With the power off, check if the pump is

free to rotate. Do this by inserting a flat

blade screwdriver into the center of the

rear bell housing engaging a slotted

screw that is present there. Apply

moderate force, if the pump will not

rotate then continue increasing force until

the pump rotates freely.

12.5 Check TP5 if the voltage is constantly

<1VDC then the problem in on the DIG-

T2 board.

12.6 If the voltage at TP5 is higher than 4DC,

then remove the JP7 connector and check

the output of JP7-1 on the AC-T1 board

to ground.

12.7 If the pump has over heated the thermal

protector will activate and stop the pump,

this can be due to a clogged or

malfunctioning chamber filter screen,

vacuum pump feed water valve (15) or

chamber vacuum valve (52).

10. TROUBLESHOOTING (cont.)

10.4 In Process Malfunction (cont.)

Symptom

12. Vacuum pump does not

work.

Page 95

Corrections

13.1 Unplug and replug in the connector

making sure good contact is made

13.2 Fix the connections

13.3 If the resistance does not correlate with

the temperature, replace the temperature

sensor.

13.4 If the display does not match the

selections on the PT100 simulator then

calibrate the temp. If unsuccessful then

replace the ANL-T2

14.1 Unplug and replug in the connector

making sure good contact is made

14.2 Fix the connections

14.3 If the resistance does not correlate with

the temperature, replace the temperature

sensor.

Possible cause check-up and tests

13.1 Check that the connector of the sensor is

properly plugged into JP2 on the ANL-

T2 board.

13.2 Check that the wires and connector are in

good condition.

13.3 Disconnect the PT100 from the connector

and check its resistance. At 32ºF the

resistance across the two wires of the

sensor should read 100 Ω. The resistance

at higher temperature can be calculated

by adding 0.2 ohms for each degree F.

13.4 Plug the PT100 simulator into the JP2

connector and try the various temperature

selections.

14.1 Check that the connector of the sensor is

properly plugged into JP2 on the ANL-

T2 board.

14.2 Check that the wires and connector are in

good condition.

14.3 Disconnect the PT100 from the connector

and check its resistance. At 32ºF the

resistance across the two wires of the

sensor should read 100 ohms. The

resistance at higher temperature can be

calculated by adding 0.2 ohms for each

degree F.

10. TROUBLESHOOTING (cont.)

10.4 In Process Malfunction (cont.)

Symptom

13. The displayed temperature

permanently indicates a

temperature higher than

284ºF or T1CUT is

displayed.

14. The displayed temperature

permanently indicates a

temperature less than 54ºF,

although chamber

temperature is high.

Page 96

Corrections

14.4 If the display does not match the

selections on the PT100 simulator then

calibrate the temp. If unsuccessful than

replace the ANL-T2

15.1 Unplug and replug in the connector

making sure good contact is made

15.2 Replace the PT100 sensor

15.3 Calibrate the system. (see para 5)

15.4 Replace ANL-T2 board and calibrate the

system.(see para 5)

16.1 Unplug and replug in the connector

making sure good contact is made

16.2 Fix the connections

16.3 Replace the pressure sensor and calibrate

(see para 5).

16.4 Replace the ANL-T2 and calibrate (see

para 5).

Possible cause check-up and tests

14.4 Plug the PT100 simulator into the JP2

connector and try the various temperature

selections.

15.1 Check that the connector of the sensor is

properly plugged into JP2 on the ANL-

T2 board.

15.2 Check the positioning of the PT100 (see

sec 9.20) If the positioning is correct then

the PT100 sensor is faulty.

15.3 The difference in the displayed

temperature when the PT100 simulator is

connected is similar, in magnitude and

direction, to the difference in the

displayed temperature when the PT100

sensor is connected.

15.4 System cannot be calibrated.

16.1 Check that the connector of the sensor is

properly plugged into JP1 on the ANL-

T2 board.

16.2 Check that the wires and connector are in

good condition.

16.3 The pressure sensor is defective.

16.4 The pressure measuring circuit on ANL-

T2 board is defective.

10. TROUBLESHOOTING (cont.)

10.4 In Process Malfunction (cont.)

Symptom

14. (cont)

15. The displayed temperature

is significantly different

from the actual

temperature.

16. The displayed pressure of

the chamber pressure

permanently indicates a

pressure over 50 psi.

Page 97

Corrections

17.1 Unplug and replug in the connector

making sure good contact is made

17.2 Fix the connections

17.3 Replace the pressure sensor and calibrate

(see para 5).

17.4 Replace the ANL-T2 and calibrate (see

para 5).

18.1 Unplug and replug in the connector

making sure good contact is made

18.2 Calibrate the system (see para 5)

18.3 Clean or replace the pressure sensor and

calibrate (see para 5).

18.4 Replace the ANL-T2 and calibrate (see

para 5).

19.1 Fix the connections.

19.2 Replace the electrode

19.3 Clean the electrode with alcohol and

check that the quality of the water used

in the jacket is as specified in the

manual.

19.4 Replace ANL- T2 board.

Possible cause check-up and tests

17.1 Check that the connector of the sensor is

properly plugged into JP1 on the ANL-

T2 board.

17.2 Check that the wires and connector are in

good condition.

17.3 The pressure sensor is defective.

17.4 The pressure measuring circuit on ANL-

T2 board is defective.

18.1 Check that the connector of the sensor is

properly plugged into JP1 on the ANL-

T2 board.

18.2 The system is out of calibration

18.3 The pressure sensor is contaminated with

dirt or is defective.

18.4 The pressure measuring circuit on ANL-

T2 board is defective.

19.1 Check if the wire connected to the

electrode is shorted to ground.

19.2 Check if the electrode is shorted to

ground.

19.3 The electrode is dirty.

19.4 If there is no short to ground then the

ANL-T2 board is bad.

10. TROUBLESHOOTING (cont.)

10.4 In Process Malfunction (cont.)

Symptom

17. The displayed pressure of

the chamber permanently

indicates a pressure less

than 7.3 psi.

18. The displayed pressure is

significantly different from

the actual pressure.

19. The electrode senses water

in the jacket, but the jacket

is empty.

Page 98

Corrections

20.1 If the float will not move freely then

replace it

20.2 Unplug and replug the connectors to

insure a good connection. Fix and broken

wires.

20.3 If the float movement does not show a

change in the meter reading then replace

the float.

20.4.1 Unplug the FC37P cable connecting the

ANL-T2 and the DIG-T2. Inspect all

connectors for bent pins. Make sure the

flat cable’s connectors are in good

condition. Reconnect the cable.

20.4.2 Replace the ANL-T2 board

20.4.3 Replace the DIG-T2

Possible cause check-up and tests

20.1 Check if the float moves up and down

freely.

20.2 Check that the wires and connectors at

the float and the connector at JP11 and

JP12 on the ANL-T2 and the four pin DC

connector plugged into the back of the

electronic box are connected securely.

20.3 Disconnect the wires of the float switch

and check with an ohmmeter. Move the

switch up and down and observe that the

meter shows an open and closed circuit

20.4 If previous checks are OK the problem

could be on the ANL-T2 or DIG-T2

boards.

10. TROUBLESHOOTING (cont.)

10.4 In Process Malfunction (cont.)

Symptom

20. The float switch in the

water reservoir is always

ON or OFF.

Page 99

Corrections

21.1 Clean the electrode with alcohol and

check that the quality of the water used

in the jacket is as specified in the

manual.

21.2 Fix the connections.

21.3 Replace the faulty electrode.

21.4 Replace ANL- T2 board.

22.1 Increase tightness if leaking occurs.

22.2 Clean the gasket or replace

22.3 The thicker part of the gasket fits into the

door groove first

22.4 If the leaking occurs in the area of the

locking device, it is most likely coming

from the door bellows.

23.1 Replace the door bellows

Possible cause check-up and tests

21.1 Electrode is not clean.

21.2 Disconnect the electrode. The displayed

number should be approx. 255. Short-

circuit the electrode by touching the

electrode housing with the wire of the

disconnected electrode. The displayed

number should be "0". If so – the electrode

is faulty.

21.3 Check for an open in the wire connecting

the electrode to the ANL-T2 board at the

JP11 connector.

21.4 If there is no open in the circuit then the

ANL-T2 board is damaged.

22.1 Make sure the door is closed tightly

22.2 Check if the gasket is clean and smooth.

22.3 Make sure the gasket is installed

correctly.

22.4 Check the door bellows.

23.1 The door bellows locking mechanism is

faulty.

10. TROUBLESHOOTING (cont.)

10.4 In Process Malfunction (cont.)

Symptom

21. The electrode does not

sense water in the jacket,

but the jacket is full.

22. Steam leaks from around

the door.

23. The door bellows locking

mechanism does not lock the

door at a pressure of 6 psig.

Page 100

24.1 Replace the DIG-T2 board.

24.2 Fix the connections.

24.3 Disassemble the valve and check that the

plunger is free to move and that the seat

is clean and free from debris.

24.4 Replace the ANL-T2 board.

Corrections

The problem may be a mechanical failure of the

valve, the valve driver located on the ANL-T2

board or the control circuit on the

DIG-T2 board.

24.1 Check TP10. If the voltage is higher than

4V and the valve is open, then the DIG-

T2 board is faulty.

If the voltage at TP10 is <1VDC and the

valve is open, the problem is not the

DIG-T2, but some other element of the

system.

24.2 Check the connection between the

connector JP10 - 6 and the valve for a

ground short.

24.3 Remove the cover protecting the

terminals of the coil and check the

voltage across the coil when the solenoid

is connected. If the coil voltage is less

than 2V and the valve is open, there is a

mechanical problem.

24.4 If the voltage across the coil is higher

than 10VDC, then the ANL-T2 board is

faulty.

Possible cause check-up and tests

24. Water valve (15) to vacuum

pump is always open.

Symptom

10. TROUBLESHOOTING (cont.)

10.4 In Process Malfunction (cont.)