Tuttnauer 2540 EHS, 3870 EHS Technician Manual

TECHNICIAN

MANUAL

Electronic Table - top

Pre and Post Vacuum Autoclaves

models 2540 & 3870 EHS

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

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

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

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

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

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

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)

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.

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

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.

REAR VIEW

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

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.

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.

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.

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).

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.

Layout diagram of the ANL-T2 is provided below.

ANL- T2 BOARD

Top View

Bottom View

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

AC-T1 BOARD

Top View

Bottom View

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.

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

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.

— 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

— 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

— 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.

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

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

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(

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

6.4 Input Output Graph:

+ 100 hidden pages

Tuttnauer 2540 EHS, 3870 EHS Technician Manual

Specifications and Main Features

Frequently Asked Questions

User Manual