Tuttnauer 6690 STS-1V Maintenance manual [gb]

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Page 1

OPERATION

MAINTENANCE

MANUAL

Prevacuum Steam Heated Autoclave

with Steam to Steam Generator

and Vertical Sliding Door

model 6690 STS-1V

S/N: 2301006, 2301007, 2301011, 2301012, 2301013,

2301014, 2301015, 2301016, 2301017, 2301018

Cat.No.: MAN205-0211-002 Rev: C

Manufactured by:  Tuttnauer Co. Ltd., P.O.Box 35292, Jerusalem, Israel Tel: 972 2 6581611, Fax: 972 2 6520271

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Page 3

Table of Contents

Incoming Inspection ---------------------------------------------------------------- 1

1. General Information

1.1 Introduction ---------------------------------------------------------------------- 2-3

1.2 Standards --------------------------------------------------------------------------- 3

1.3 Specifications ----------------------------------------------------------------------- 4

1.4 Steam Data-------------------------------------------------------------------------- 4

2. Functional Description

2.1 The Steam to Steam Generator ----------------------------------------------- 5

2.2 The Water Pump------------------------------------------------------------------- 5

2.3 The Piping System ------------------------------------------------------------- 6-7

2.4 The Pneumatic Control System -------------------------------------------- 8-9

2.5 The Water Quality ---------------------------------------------------------- 10-11

2.6 The Electric System ------------------------------------------------------------ 12

2.7 Control System -------------------------------------------------------------- 13-15

3. Sterilization Programs --------------------------------------------------- 16-39

4. Control and Monitoring

♦ Control Panel 'CAT 2007' --------------------------------------------------------40

4.1 Description of panel 'CAT 2007'---------------------------------------------- 41

4.1.1 Keypad ----------------------------------------------------------------- 41-42

4.1.2 Display ----------------------------------------------------------------- 43-44

4.2 Description of Displayed Messages and Safety Measures ------- 45-46

4.3 Operating the Control Panel

4.3.1 Starting up the system ------------------------------------------------- 47

4.3.2 Selecting a Cycle ---------------------------------------------------- 48-50

4.3.3 System Setup -------------------------------------------------------- 51-53

4.3.4 Changing cycle parameters -------------------------------------- 54-58

4.3.5 Test Programs ------------------------------------------------------- 59-60

4.3.6 Display function ---------------------------------------------------------- 61

4.3.7 Display during a cycle ---------------------------------------------- 62-63

5. Calibration ------------------------------------------------------------------------- 64

5.1 Calibrating temperature and pressure ------------------------------------- 65

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Table of Contents

5.1.1 Temp 1 --------------------------------------------------------------------- 65

5.1.2 Temp 2 --------------------------------------------------------------------- 66

5.1.3 Temp 3 --------------------------------------------------------------------- 66

5.1.4 Temp 4 --------------------------------------------------------------------- 66

5.1.5 Chamber Pres ------------------------------------------------------------ 66

5.1.6 Jacket Pres ---------------------------------------------------------------- 66

5.1.7 Gen Pres ------------------------------------------------------------------- 66

5.1.8 D1 Pres----------------------------------------------------------------- 66-67

6. Transportation of the Autoclave -------------------------------------------- 68

7. Preparation before Sterilization----------------------------------------- 69-70

♦ Loading and Unloading ---------------------------------------------------------70

8. Installation Instructions --------------------------------------------------- 71-72

9. Operating Instructions -------------------------------------------------------- 73

♦ Control Panel -----------------------------------------------------------------------74

10. Printer

10.1 Printer Operation ---------------------------------------------------------- 75-76

10.2 Printer Handling --------------------------------------------------------------- 77

11. Maintenance of the Autoclave

11.1 Preventive and Periodical Maintenance --------------------------------- 78

SERVICE INSTRUCTIONS

11.2 Safety Tests after Repair----------------------------------------------------- 80

11.3 Troubleshooting ------------------------------------------------------------ 81-85

11.4 Troubleshooting for the Water Pump ‘SHURFLO’ --------------------- 86

11.5 Pressure Switch --------------------------------------------------------------- 87

11.6 Absolute Pressure Transducer --------------------------------------------- 88

11.7 Cleaning and replacing the Water Level Electrodes ------------------ 89

11.8 The GEN - PROTEC electronic board ------------------------------------ 90

11.9 Water Pump Rear Endbell Replacement Kit ------------------------ 91-92

11. 10 Door Oil Piston --------------------------------------------------------------- 93

11.10 Dismantling the Cabinets side panels ---------------------------------- 94

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Table of Contents

12. Spare Parts ------------------------------------------------------------------ 95-96

13. Valves Numbering -------------------------------------------------------- 97-98

14. Pressure and Temperature Table for Saturated Steam------------ 99

Drawings

♦ The Pneumatic Control System Drawing ------------------------------------- 9

♦ Vertical Sliding Door------------------------------------------------------------- 100

♦ Vertical Door- Locking Mechanism ------------------------------------------101

♦ Piping drawing ------------------------------------------------------------------- 102

♦ Electric drawing for the Autoclave ------------------------------------------- 103

XPCS Manual ------------------------------------------------------------------104-117

♦ Steps for modem connection-------------------------------------------------- 117

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INCOMING INSPECTION

The instruments (products) should be unpacked and inspected for mechanical damage upon receipt. Observe packing method and retain packing materials until the unit has been inspected. Mechanical inspection involved checking for signs of physical damage such as: scratched panel surfaces, broken knobs, etc.

If damage is apparent, file a claim with the carrier. The manufacturer is responsible for products shipped F.O.B. These products are carefully inspected prior to shipment and all reasonable precautions are taken in preparing them for shipment to assure safe arrival at their destination.

WARRANTY

We certify that this instrument is guaranteed to be free from defects in material and workmanship for one year against faulty components and assembly with the exception of glassware, lamps and heaters. The warranty does not include and does not replace routine treatment and preventive maintenance to be performed according to instructions in paragraph 11.1 'Preventive and Periodical Maintenance'.

Our obligation is limited to replacing the instrument or parts, after our examination, if within one year after the date of shipment they prove to be defective. This warranty does not apply to any instrument, which has been subjected to misuse, neglect, accident or improper installation or application, nor shall it extend to products, which have been repaired or altered outside the factory without prior authorization from us.

The Autoclave should not be used in a manner not described in this manual!

Note

If there is any difficulty with this instrument, and the solution is not covered in this manual, contact our representative or us first.

Do not attempt to service this instrument yourself.

Stipulate the model and serial number and describe the difficulty as clearly as possible so we may be able to diagnose the problem and hence provide a prompt solution.

For technical information or service please contact our representative at:

 Tuttnauer USA Co. 25 Power Drive Hauppauge NY, 11788, USA  Tel:(800)624 5836, (631)737 4850

¬Fax:(631)737 07 20

Email: info@tuttnauer.com

Our web site: www.tuttnauer.com

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1. GENERAL INFORMATION

1.1 Introduction

This autoclave is a pre-vacuum sterilizer designed to cover a large field of applications

for hospitals and medical centers as well as pharmaceutical and biotechnological

industries.

The autoclave operates with saturated steam as the sterilizing agent, and has a

temperature of up to 279ºF and pressure up to 40 psi.

The autoclave is constructed of stainless steel, having a double - walled structure

and is equipped with a steam to steam generator, which supplies clean steam to the

chamber for the sterilization process. There are separate steam lines from the steam

to steam generator to the chamber and from the building steam supply to the jacket.

The autoclave is equipped with one vertical sliding door operated by a hydraulic

system, through two oil cylinders mounted laterally on both sides of the door. The

command pressure of compressed air is transmitted to the oil in the cylinders and

converted into hydraulic pressure, which pushes the pistons up or down, for closing

or opening the door.

The sealing of the chamber is achieved through a heat resistant silicone gasket,

located in a groove on the front side of the autoclave. The gasket is pushed against

the door by steam pressure introduced in the groove, behind the gasket.

Twelve sterilization programs are available, four are intended for unwrapped

instruments (gravity), four for wrapped instruments and packages and four for liquids.

Two test programs are also available, the VACUUM TEST for checking the tightness

of the chamber and piping system and the BOWIE DICK test enabling to check the

efficiency of the sterilization process.

The control system of the sterilizer is based on " State-of -the -Art" microcomputer

technology, ensuring a highly reliable and safe operation. The computerized control unit

ensures a fully automatic operation through the entire cycle, hence after setting the

pre-selected data and starting the operation, no further intervention is necessary.

The selected program, the main phases of the cycle and the status of the machine are

controlled and displayed on digital readouts. For process documentation, the important

information concerning operation is printed in hard copy.

For optimal control accuracy of the sterilization parameters, the system is equipped with

three temperature sensors, three pressure transducers and a pressure switch having

the following functions:

♦ The temperature sensors: 2 measuring the condense temperature (control and printout)

and the drain control output.

♦ The pressure transducers: the chamber pressure (control and monitoring), the jacket

pressure (control) and gasket pressure.

♦ The pressure switch regulates the steam pressure output of the steam generator.

Four pressure gauges measure the gasket, jacket, chamber and steam generator

pressure.

A programming mode, which can be entered by an access code, enables the technician

to set a number of additional parameters and operation modes.

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The keyboard located on the front panel enables the operator to start and stop the

cycle.

Only the responsible person has access to select the program and change the

major parameters by using the key.

Optionally, a personal computer can be connected to the control system, through the

interface board RS232, which can be, operated 8 meters away from the autoclave.

The PC, operating under WINDOWS displays the status, data and processing in real

time in graphic and digital form at the same time recording and logging the data.

The communication PC-control unit enables the complete control of the autoclave

through the PC, including program selection, starting and stopping the cycle, setting

of parameters and the real time clock (data and time of the day).

1.2 Standards

This autoclave meets applicable requirements of the following standards:

1. A.S.M.E. Code, Section VIII Division 1 for unfired pressure vessels.

2. HTM 2010 – Sterilization and HTM 2031 - Clean Steam for Sterilization.

3. Complies with AAMI/ANSE ST8- Hospital Steam Sterilizers.

4. Complies with Underwriters Laboratories (U.L 2601-1) requirements

Tuttnauer is approved for ISO 9002 (Quality Systems), EN 46002 (Quality

Systems for Medical Devices) and ISO 13488 (Quality systems for Medical

devices – Particular requirements for the application of ISO 9002).

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1.3 Specifications

Product data

Chamber Dim.

Model 6690 – 1V

26’’ (660 mm.) 26’’ (660 mm.)

36’’ (1070 mm.)

Chamber volume 467 l.

1215 mm.

1990 mm.External dim.

1450 mm.

Net Weight 1150 kg (2540 lb)

Degree of protection

IPX 4

Utilities

1’’, 50-80 PSI,

Steam supply

Cold water supply

Maximum hardness value 72-215 TDS of CaCO

Recommended temperature 59°F

Compressed air requirements

Electrical data:

Pressure 90-110 PSI, 3.5 SCFM

160 Lbs/Hr Peak

88 Lbs/Hr Av ¾’’, 50-80 PSI,

12.5 GPM Peak 275 GPH Avg.

3/8" thread connection.

Voltage 1 ph, 115V/60Hz

Current

1.4 Steam Data

Working pressure

Test pressure

Safety relief valve

Plant Steam (Input) Generated Steam (Output)

pressure

(bar)

8 176 137 2.6 140 116

7 171 88 2.6 140 80

6 165 52 2.6 140 47

5 159 24 2.6 140 22

Utility 10 A

Consumption 6A

4 Bar (59 psi)

15.5 Bar (228 psi)

5 Bar (75 psi)

Temp.

(°C)

Rate Kg/h

pressure

(bar)

Temp.

(°C)

Rate Kg/h

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2. FUNCTIONAL DESCRIPTION

2.1 The Steam to Steam Generator

The steam for the sterilization process is supplied from the building main steam supply to a built in steam to steam generator, which produces clean steam and is directly connected to the autoclave chamber. Water to the steam generator is supplied by a single-phase pump, from a water reservoir, which is connected to a source of distilled or mineral free water. A water level control system, consisting of two electrodes mounted on top of the boiler and connected to the electronic control board maintains through the pump and a solenoid valve, a constant water level and ensures a safe operation of the steam to steam generator. A pressure switch connected through the electronic board regulates the output steam pressure. A safety relief valve blows off at a pressure of 40 psi, to prevent build-up of overpressure in case of control failure.

Only mineral - free water or distilled water will be used for operation of the generator. See also par. 2.5 ‘Water Quality’.

2.2 Water Pump for the Steam Generator

The suction of the pump is connected to the water reservoir filled with mineral-free water and mounted on the side of the autoclave. The mineral water is heated to 80ºC and maintained at this temperature so that the steam obtained from this water has a low content of non-condensable gases. A PT100 temperature sensor controls the water temperature.

A float valve keeps a constant level of water and prevents an overflow of water out of the reservoir.

A lower float switch stops the operation of pump and heaters, when the water level drops below this switch.

The Vacuum Breaker

When the generator cools down, it generates vacuum inside. The vacuum breaker breaks it so that the generator won’t draw water from the mineral free water reservoir.

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2.3 The Piping System

The piping system of the autoclave consists of air-operated ball valves, which control the water, condensate and steam flow in and out of the chamber, operate the vacuum pump, and the air inlet valve. The air pulses to the pneumatic valves is transmitted through solenoid pilot valves, operated at 24VDC.

The functions of the valves are as follows:

Air-operated valves

Steam to jacket (91); introduces steam from outer source to jacket, to heat the jacket during the sterilization phase.

Steam to chamber valve (93); introduces clean steam from the steam to steam generator into the chamber, for heating and maintaining the chamber temperature during the sterilization phase.

Steam inlet to the generator valve (95); introduces steam from the building steam supply into the steam to steam generator for producing clean steam.

Air inlet valve (43); introduces filtered atmospheric air at the end of the cycle to break the vacuum and enable the opening of the door.

Fast exhaust to drain valve (73); evacuates the steam from the chamber to drain at a fast rate, until pressure goes down to zero, in the prevacuum and post sterilization phases.

Condense valve (74); evacuates the condense from the chamber in the heating and sterilization phases and isolates the chamber from the drain pipe during the vacuum generation. It operates like a slow exhaust valve at the end of the liquids program.

Exhaust to ejector valve (75); works together with the vacuum valve and connects the chamber to ejector to create vacuum in the chamber.

Feed water to ejector valve (15); controls the flow of water through the ejector to produce vacuum in the prevacuum and dry stages.

Mineral free water inlet valve (21); flows water from the mineral free water reservoir and prevents hot water to return from the steam to steam generator to the reservoir.

Drain cooling valve (13); flows water to drain, to cool the drain during the steam and condense evacuation.

Pressure to gasket valve (94); controls the compressed air pressure to the door gasket. When the door is closed, air enters through the valve into the groove behind the gasket pushing it against the door to seal the chamber.

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Vacuum to gasket valve (53); connects the gasket groove to the ejector. While the door is moving during the opening or closing - the valve is open and vacuum is produced to pull the gasket inside the groove, ensuring the smooth sliding of the door. When the door is open, this valve is operated but vacuum is not produced. The commands of the two valves are achieved by means of two solenoid valves. The two valves work in opposition, at any moment when one of them is open the other is closed, as described above.

Solenoid - Operated Valves

Besides the pilot solenoid valves which control the air - operated valves, the following solenoid valves have direct action as described below:

Close door valve(39); is a solenoid valve which transmits compressed air to the door cylinders for closing the door.

Open door valve(38); is a solenoid valve which transmits compressed air to the door cylinders for opening the door.

Air supply valve (31); is a solenoid valve which transmits compressed air to the manifold branch solenoid battery for the command of pneumatic valves. It ensures that the valves control and doors driving are active, only if the electrical power supply is present.

Note: The valves numbers are in accordance with the valve numbering list and piping diagram at the end of the manual.

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2.4 The Pneumatic Control System

The control of the pneumatic valves is done through compressed air, as described below: The pneumatic valves are air-air control type, fitted with two commands, an opening command received through solenoid valve at a pressure of 6 bars - output by the control system and a permanent closing command at a pressure of 3 bars, connected to all valves.

The pneumatic control system is built as follows (refer to drawing on the next page). The incoming compressed air supply at a pressure of 7-8 bars is set by means of a pressure regulator at 6 bars and transmitted to the entrance of the pilot solenoid valve battery.

The solenoid valve battery is mounted on a manifold branch base, through which all the solenoids are connected to the compressed air supply.

At the output side of the manifold branch, a pressure regulator at 3 bars sets the compressed air.

As long as a pneumatic valve does not receive from the control system an opening command the close command which is permanently present will determine the shut-off position of the valve.

When an open command at 6 bars reaches a pneumatic valve, it overcomes the opposite close command at 3 bars, and sets up the valve in position open. A non-return valve mounted between the outlet side of the manifold branch and the pressure reducer prevents the flow of air from the air reservoir to the solenoid battery.

One safety measure is provided, a pneumatic control three-way, two-position steam activated air returned valve

when pressure is introduced in the chamber.

to prevent the possibility of opening the door

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2.5 Water Quality

2.5.1 Steam to Steam Generator

The distilled or mineral – free water supplied to the steam to steam generator should have the physical characteristics and maximum acceptable level of contaminants indicated in the table below:

Physical Characteristics and Maximum acceptable contaminants levels

in water or steam, for steam generator

(In compliance with ISO 11134 and ISO 13683).

Evaporate residue

Silica

Iron

Cadmium

Lead

Rest of heavy metals

Chloride

Phosphate

Conductivity

Appearance

colorless, clean, without

< 15 mg/l

< 2 mg/l

< 0.2mg/l

< 0.005 mg/l

< 0.05 mg/l

< 0.1 mg/l

< 3 mg/l

< 0.5 mg/l

< 50 µs/cm

6.5 to 8

sediment

Hardness

< 0.1 mmol/l

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

Attention: The use of water for autoclaves that do not comply with the table above may have severe impact on the working life of the sterilizer and can invalidate the manufacturer’s guarantee. The use of soft water is strictly forbidden!

2.5.2 Water for the Vacuum System and the Drain Cooling

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

♦ Hardness: 0.7 - 2 mmol/l, 4-12 °(German) of CaCO3,

7.2-21°(French) of CaCO3, 72- 215 mg/l of CaCO

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2.5.3 Reverse Osmosis

A Reverse Osmosis (RO) system may be used to improve the quality of the water used to generate steam in the autoclave chamber.

In RO, the water is forced through a semi-penetrable membrane, which filters out contaminants to a high degree of efficiency. In deionisation (DI) ions and charged particles are removed either by electric fields or by ion exchange in resin beds.

Although the RO cannot normally attain the degree of purity possible with the DI methods, it is more than adequate for the feed water intended for clean-steam generators.

Moreover the RO has several advantages:

1. RO is cheaper to install and to run than DI.

2. RO removes particulate matter, organic molecules and pyrogens that DI cannot remove

3. RO water is less corrosive to steel and copper than DI water.

4. RO maintenance requirements are less demanding than those of the DI units.

Therefore the use of mineral free water will contribute to better performance and longer life of the autoclave.

NOTE! Please consult a water specialist.

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2.6 The Electric System

The electric system of the autoclave comprises of the power circuits, including the commands, switching and protective components, required for the operation of the electric equipment of the machine.

The following parts are located in the electric box, mounted on the side of the autoclave.

♦ The solid state relays for the command of the heaters, water pump and

ejector.

♦ The circuit breakers for protection of all power circuits. ♦ The power supply for powering of electronic circuitry and solenoid

valves. ♦ Two protective relays. ♦ The wiring and connection elements. ♦ The main switch.

The power circuits of the steam generator and the vacuum system are connected to the terminals in the electric box at a one-phase voltage, 1x 115V\60Hz. It is important to achieve a steadfast grounding screw connection to the metal-sheet enclosure of the electric box and metal parts of the autoclave.

The earth installation at the customer’s site must be built in compliance with the laws and regulations in force and International EN 61010-1 electrical safety standards and certified by the competent authorities.

Description of the Electrical Equipment

The command signal for the contactor is output by the micro-controller through a solid state relay. The water pump of the generator is driven by the solid state relay, the command signals are output by the micro-controller system. The command circuits are energized by a power supply with four outputs, as indicated below:

♦ 5 VDC for the digital circuits. ♦ +12VDC and – 12VDC for the analog circuits

♦ 24 VDC for the solenoid valves. The coils of the solenoid valves are connected with an end at +24V and with the other end to the control output of the controller. The command is active; i.e. the solenoid valve is actuated when the control voltage output is low (less than 2V) with respect to ground. Circuit breakers attain the protection of the electric and electronic circuits operated in direct current and current limiting circuits, inside the power supply stabilizers. Two protective relays are designed to stop the pump operation in case of interruption of the other phases and save the important data from the RAM memory in case of power failure.

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2.8 Control System

The Main Board

Contains the electronic microcontroller system, which controls and monitors the physical parameters of the process and performs the operation sequence of the machine according to the selected program. The dimensions of the main board are 30x15x10cm. The main board contains the following elements:

♦ 16 digital inputs ♦ 24 digital outputs ♦ 6 PT 100 inputs ♦ 7 Inputs of 4 –20mA ♦ voltage inputs for the electrode for water level ♦ 2 analog outputs of 4 –20mA ♦ Serial ports ♦ CPU.

♦ 2 ADC's for reading temperature and pressure sensors. Each ADC maintains at least 3 temperature sensors (PT100), and 3 pressure sensors (4 –20mA). All connections to the main board are via rigid contactors for quick, efficient and dismantling and transport.

Digital Inputs

The digital inputs are φ/1:

♦ open/close for door positions

♦ safety cut-off switches

♦ pressure cut-off switches

♦ cut-off switches for water level The input voltage will not exceed 24VDC. The input must be protected from high voltages by means of an Opto-coupler.

Digital Outputs

Digital outputs are used to activate solenoid valves, relays and SSR for the pump. The command is 24 VDC, but this will be able to be changed and allowed to move between 10-30VDC. Each output is up to 2A, however all the outputs together will not have a capacity greater than 110 W.

Analog inputs for Reading Temperature

Temperature is measured using PT100. The system contains 2 ADC components, each component being able to read 3 PT100 sensors. The system contains circuits with a straight connection of PT100 (3 wires) that do not interchange on the way. The measurement range is 77-302

F(25-150ºC). The resolution range is 32.18oF (0.1ºC). The accuracy of the measure is 33.8oF (1ºC). The accuracy surrounding the sterilization temperature at the time of sterilization is in the range of + 32.9oF (0.5ºC). Calibration of the temperature circuit requires a special code.

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Analog Inputs for Reading Pressure

The system contains 6 inputs for reading pressure from 4 – 20mA sensors. There are at least 3 sensors on each ADC. The pressure reading occurs from inside the chamber, the steam entrance, and sealed doors. Each sensor has an output of 4mA. The system allows the measurement range of the sensor to be set by external software.

Measuring pressure in chamber

The display and printing scale is in kPa. The measurement range is 0-400kPa absolute. The resolution measurement and display is 1 kPa. The accuracy of the measurement is a maximum 1% from the range, i.e.4kPa Calibration of the pressure circuit needs a special code.

Measuring jacket pressure

The measurement range is 0-400kPa absolute. The resolution measurement and display is 1 kPa. The accuracy of the measurement is a maximum 1% from the range, i.e. 4kPa Calibration of the pressure circuit needs a special code.

Measuring generator pressure

The measurement range is 100-600 kPa (absolute). The resolution measurement and display is 2kPa. The accuracy of the measurement is maximum 1%from the range i.e. 5kPa. Calibration of the pressure circuit needs a special code.

Measuring the pressure of a gasket

The measurement range is 0 – 400 kPa absolute. The resolution measurement and display is 1kPa. The accuracy of the measurement is maximum 1% from the range, i.e. 4kPa Calibration of the pressure circuit will need a special tool or code.

Voltage Inputs for Water Level Electrodes

Water level electrodes may be placed at a few points in the autoclave. Due the experience accumulated at “Tuttnauer”, it was determined a maximum of 3 water-level measuring points are required for the sterilization process. The points are as described below: If the autoclave is equipped with a steam generator, 2 water level measuring point are required. The lower electrode stops the operation of the generator if the water level decreases below the minimum required to produce steam. The upper electrode controls the switching on of the water pump. When sterilization or cooling is performed by water entering the chamber, water level measuring is required. This measuring is performed by one water level electrode. The electrode used for measuring water level is made of a gold-coated stainless steel rod. The electrode closes an electric circuit when its tip touches the water.

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4 Serial Ports

The control system contains 4 serial ports according to the following specifications:

♦ Serial Ports for the connection of up to 2 command panels (RS485). ♦ 1 Serial Port connected to an external PC computer (RS232). ♦ 1 Serial Port connected to an internal PC computer that will work as an

activating panel (RS232).

If it will be necessary to convert some functions or to reprogram or to reload the software of the autoclave from distance, a modem can be connected using above-mentioned ports. This enables the service technicians to attend the machine from miles away, using the ADMC software thus allowing full control of the machines.

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3. STERILIZATION PROGRAMS

Following are the names, relevant programs with related temperatures of the 12 sterilization cycles and 2 test programs, which are pre-set by the manufacturer.

Cycle no. Program Temp. ºF 010203 &4 0506070809091011 & 1213 14-

3.1 Programs description

If vacuum pulse is determined '= 0' in any program by the operator, the program can be used as a 'Gravity' program. A message 'Gravity' is displayed on the right side of the screen.

Program 1 - for Unwrapped goods (Fast 250)

This program is intended for unwrapped rigid (like instruments) and other goods, which its manufacturer declares their compliance to be sterilized in the following conditions:

♦ Sterilization temperature 250ºF ♦ Sterilization time: 15 mins. ♦ Dry time: 10 mins.

Performance description:

Residual air is displaced due to 3 vacuum pulses (down to 25 kPa) and 2 steam

pulses up to 199 kPa. The third vacuum pulse is followed with introducing saturated (controlled) steam into the chamber to the required sterilization temperature. Sterilization period is controlled in a way that the sterilization temperature will not drop below the required temperature, neither will increase by more than 37.4ºF. The saturated steam conditions are controlled in such a way that fluctuation of pressure does not allow a drop below 1kPa, neither an increase of 3 kPa above the high limit of the Ste. Temperature. Fast exhaust stage is performed by discharging rapidly the pressure from the chamber. When the pressure reaches a level of 115 kPa the ejector is activated until a pressure drop to 25 kPa. Pressure equilibration. To enable the door to be opened, air is introduced to the chamber through a microbiological filter till the equilibration with atmospheric pressure.

Note:

The temperature of the chamber must be below 230ºF and the pressure must be below 115 kPa to enable the door to be opened.

Unwrapped 250 Unwrapped 250 Unwrapped 270/274 Wrapped 270 Wrapped 270 Wrapped 274 Wrapped 270 Liquids 250 Liquids 250 Liquids 250 Liquids 250 B&D test Leak test

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;

Program: 1- Fast 250

Front door close Msw

PT100 Drain Control 5

PT100 Condense 1 PT100 Condense 2 IMT Jacket IMT Chamber

Open door Close door

Ejector

Buzzer

13 – Cool drain

15 – Water to ejector

43 – Air inlet

73 – Fast exh 74 – Slow exh. 75 – Vacuum

97 – Steam to jacket

93 – Steam to chamber

273ºF / 310kPa

Condition to open T<230ºF

P<115kPa

250ºF/ ~ 210kPa

199kPa

230ºF / ~ 115kPa 100kPa

50kPa 25kPa

0kPa

Start (Close door)

Door secure Temp. control Pres. Control On (activated)

250ºF 15min.

115kPa

Ex. Mode 1

10 min

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Program 2 - for Unwrapped goods (Fast 250)

This program is intended for unwrapped rigids (like instruments) and other

goods, which its manufacturer declares their compliance to be sterilized in the

following conditions:

♦ Sterilization temperature 250ºF ♦ Sterilization time: 15 mins. ♦ Dry time: 10 mins.

Performance description:

Residual air is displaced due to 3 vacuum pulses (down to 25 kPa) and

2 steam pulses up to 199 kPa. The third vacuum pulse is followed with

introducing saturated (controlled) steam into the chamber to the required

sterilization temperature.

Sterilization period is controlled in such a way that the sterilization

temperature will not drop below the required temperature, neither will increase by more than 37.4ºF. The saturated steam conditions are controlled in such a way that the fluctuation of pressure does not allow a drop below 1kPa , neither an increase of 3 kPa above the high limit of the Ste. Temperature.

Fast exhaust stage is performed by discharging rapidly the pressure from the chamber. When the pressure reaches a level of 115 kPa the ejector is

activated till a pressure drop to 25 kPa.

Pressure equilibration. To enable the door to be opened, air is introduced to the chamber through a microbiological filter till the equilibration with

atmospheric pressure.

Note:

The temperature of the chamber must be below 230ºF and the pressure must be below 115 kPa to enable the door to be opened.

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;

Program: 2- Fast 250

Front door close Msw PT100 Drain Control 5 PT100 Condense 1 PT100 Condense 2 IMT Jacket IMT Chamber

Open door Close door

Ejector

Buzzer

13 – Cool drain 15 – Water to ejector 43 – Air inlet

73 – Fast exh 74 – Slow exh. 75 – Vacuum 97 – Steam to jacket 93 – Steam to chamber

Condition to open T<230ºF

P<115kPa

273ºF / 310kPa

250ºF / ~ 210kPa

199 kPa

230ºF / ~ 115kPa 100kPa

50kPa 25kPa

0kPa

Start (Close door)

Door secure Temp. control Pres. control On (activated)

250ºF- 15min.

115kPa

Ex. Mode 1

10 min

Page 19 of 117 pages

Page 25

Program 3 & 4 - for Unwrapped goods (Fast 270/274)

This program is intended for unwrapped rigids (like instruments) and other goods, which its manufacturer declares their compliance to be sterilized in the following conditions:

♦ Sterilization temperature 270ºF (for program 3) and 274ºF (for program 4) ♦ Sterilization time: 5 mins. ♦ Dry time: 15 mins.

Performance description: Residual air is displaced due to 3 vacuum pulses (down to 25 kPa) and 2

steam pulses up to 199 kPa. The third vacuum pulse is followed with introducing saturated (controlled) steam into the chamber to the required sterilization temperature.

Sterilization period is controlled in such a way that the sterilization temperature will not drop below the required temperature, neither will increase by more than 37.4ºF. The saturated steam conditions are controlled in such a way that the fluctuation of pressure does not allow a drop below 1kPa, neither an increase of 3 kPa above the high limit of the Ste. Temperature.

Fast exhaust stage is performed by discharging rapidly the pressure from the chamber. When the pressure reaches a level of 115 kPa the ejector is activated till a pressure drop to 25 kPa.

Pressure equilibration. To enable the door to be opened, air is introduced to the chamber through a microbiological filter till the equilibration with atmospheric pressure.

Note:

The temperature of the chamber must be below 230ºF and the pressure must be below 115 kPa to enable the door to be opened.

Page 20 of 117 pages

Page 26

Program: 3 & 4 - (Fast 270 / 274)

;

Front door close Msw PT100 Drain Control 5 PT100 Condense 1 PT100 Condense 2 IMT Jacket IMT Chamber

Open door Close door

Ejector

Buzzer

13 – Cool drain 15 – Water to ejector 43 – Air inlet

73 – Fast exh 74 – Slow exh. 75 – Vacuum 97 – Steam to jacket 93 – Steam to chamber

273ºF / 310kPa

Condition to open T<230ºF

P<115kPa

270/274ºF / ~ 210kPa

199 kPa

230ºF / ~ 115kPa 100kPa

50kPa 25kPa

0kPa

Start (Close door)

Door secure Temp. control Pres. control On (activate

270/274ºF 5min.

Ex. Mode 1

115kPa

15 min

Page 21 of 117 pages

Page 27

Program 5 - for Wrapped goods (with Dry 270)

This program is intended for wrapped materials (like instruments), porous load and other goods, which its manufacturer declares their compliance to be sterilized in the following conditions:

♦ Sterilization temperature 270ºF ♦ Sterilization time: 3 mins. ♦ Dry time: 15 mins.

Performance description: Residual air is displaced due to 4 vacuum pulses (down to 25 kPa) and 3

steam pulses up to 199 kPa. The 4th vacuum pulse is followed with introducing saturated (controlled) steam into the chamber to the required sterilization temperature.

Sterilization period is controlled in a way that the sterilization temperature will not drop below the required temperature, neither increase by more than

37.4ºF. The saturated steam conditions are controlled in a way that the fluctuation of pressure does not allow a drop below 1kPa, neither an increase of 3 kPa above the high limit of the Ste. Temperature.

Fast exhaust stage is performed by discharging rapidly the pressure from the chamber. When the pressure reaches a level of 115 kPa the ejector is activated till a pressure drop to 25 kPa.

Drying is achieved by evacuating the vapor from the chamber in "under-pressure” phase along a period of 15 minutes.

Pressure equilibration. To enable the door to be opened, air is introduced to the chamber through a microbiological filter till the equilibration with atmospheric pressure.

Note:

The temperature of the chamber must be below 230ºF and the pressure must be below 115 kPa to enable the door to be opened.

Page 22 of 117 pages

Page 28

Program: 5- for Wrapped goods (with Dry 270)

;

Front door close Msw PT100 Drain Control 5 PT100 Condense 1 PT100 Condense 2 IMT Jacket IMT Chamber

Open door Close door

Ejector

Buzzer

13 – Cool drain 15 – Water to ejector 43 – Air inlet

73 – Fast exh 74 – Slow exh. 75 – Vacuum 92 – Steam to jacket 93 – Steam to chamber

273ºF / 310kPa

Condition to open T<230ºF

P<115kPa

270ºF / ~ 210kPa

199kPa

230ºF / ~ 115kPa 100kPa

50kPa 25kPa

0kPa

Start (Close door)

Door secure Temp. control Pres. control On (activated)

270ºF 3min.

Ex. Mode 1

115kPa

15min

Page 23 of 117 pages

Page 29

Program 6 - for Wrapped goods (with Dry 270)

This program is intended for wrapped materials (like instruments), porous load and other goods, which its manufacturer declares their compliance to be sterilized in the following conditions:

♦ Sterilization temperature 270ºF ♦ Sterilization time: 10 mins. ♦ Dry time: 10 mins.

Performance description: Residual air is displaced due to 4 vacuum pulses (down to 25 kPa) and 3

steam pulses up to 199 kPa. The 4th vacuum pulse is followed with introducing saturated (controlled) steam into the chamber to the required sterilization temperature.

Fast exhaust stage is performed by discharging rapidly the pressure from the chamber. When the pressure reaches a level of 115 kPa the ejector is activated till a pressure drop to 25 kPa .

Drying is achieved by evacuating the vapor from the chamber in "under-pressure” phase along a period of 15 minutes.

Pressure equilibration. To enable the door to be opened, air is introduced to the chamber through a microbiological filter till the equilibration with atmospheric pressure.

Note:

The temperature of the chamber must be below 230ºF and the pressure must be below 115 kPa to enable the door to be opened.

Page 24 of 117 pages

Page 30

Program: 6- Wrapped goods - with Dry (270)

Front door close Msw PT100 Drain Control 5 PT100 Condense 1 PT100 Condense 2 IMT Jacket IMT Chamber

Open front door Close front door

Ejector

Buzzer

13 – Cool drain 15 – Water to ejector 43 – Air inlet

73 – Fast exh 74 – Slow exh. 75 – Vacuum 97 – Steam to jacket 93 – Steam to chamber

273ºF / 310kPa

270ºF / ~ 210kPa

199 kPa

230ºF / ~ 115kPa 100kPa

Condition to open T<230ºc ; P<115kPa

270ºF 10min.

115kPa

Ex. Mode

50kPa 25kPa

0kPa

Start (Close door)

Door secure Temp. control Pres. control On (activated)

10min

Page 25 of 117 pages

Page 31

Program 7- for Wrapped materials (with Dry 274)

This program is intended for wrapped materials (like instruments), porous load and other goods, which its manufacturer declares their compliance to be sterilized in the following conditions:

♦ Sterilization temperature 274ºF ♦ Sterilization time: 7 mins. ♦ Drying period of 15 mins.

Performance description: Residual air is displaced due to 4 vacuum pulses (down to 25 kPa) and 3

steam pulses up to 199 kPa. The 4th vacuum pulse is followed with introducing saturated (controlled) steam into the chamber to the required sterilization temperature.

Fast exhaust stage is performed by discharging rapidly the pressure from the chamber. When the pressure reaches a level of 115 kPa the ejector is activated till a pressure drop to 25 kPa .

Drying is achieved by evacuating the vapor from the chamber in "under-pressure” phase along a period of 15 minutes.

Pressure equilibration. To enable the door to be opened, air is introduced to the chamber through a microbiological filter till the equilibration with atmospheric pressure.

Note:

The temperature of the chamber must be below 230ºF and the pressure must be below 115 kPa to enable the door to be opened.

Page 26 of 117 pages

Page 32

Program: 7- Wrapped goods - with Dry (274)

Front door close Msw PT100 Drain Control 5 PT100 Condense 1 PT100 Condense 2 IMT Jacket IMT Chamber

Open front door Close front door

Ejector

Buzzer

13 – Cool drain 15 – Water to ejector 43 – Air inlet

73 – Fast exh 74 – Slow exh. 75 – Vacuum 97 – Steam to jacket 93 – Steam to chamber

273ºF / 310kPa

274ºF / ~ 210kPa

199kPa

230ºF / ~ 115kPa 100kPa

274ºF 7min.

Ex. Mode 1

Condition to open T<230ºF ; P<115kPa

50kPa 25kPa

0kPa

Start (Close door)

Door secure Temp. control Pres. control On (activated)

115kPa

15min

Page 27 of 117 pages

Page 33

Program 8 (with Dry 270)

This program is intended for wrapped materials (like instruments), porous load and other goods, which its manufacturer declares their compliance to be sterilized in the following conditions:

♦ Sterilization temperature 270ºF ♦ Sterilization time: 3 mins. ♦ Dry time: 10 mins.

Performance description: Residual air is displaced due to 4 vacuum pulses (down to 25 kPa) and 3

steam pulses up to 199 kPa. The 4th vacuum pulse is followed with introducing saturated (controlled) steam into the chamber to the required sterilization temperature.

Fast exhaust stage is performed by discharging rapidly the pressure from the chamber. When the pressure reaches a level of 115 kPa the ejector is activated till a pressure drop to 25 kPa .

Drying is achieved by evacuating the vapor from the chamber in "under-pressure” phase along a period of 15 minutes.

Pressure equilibration. To enable the door to be opened, air is introduced to the chamber through a microbiological filter till the equilibration with atmospheric pressure.

Note:

The temperature of the chamber must be below 230ºF and the pressure must be below 115 kPa to enable the door to be opened.

Page 28 of 117 pages

Page 34

Program: 8- Wrapped goods - with Dry (270)

Front door close Msw PT100 Drain Control 5 PT100 Condense 1 PT100 Condense 2 IMT Jacket IMT Chamber

Open front door Close front door

Ejector

Buzzer

13 – Cool drain 15 – Water to ejector 43 – Air inlet

73 – Fast exh 74 – Slow exh. 75 – Vacuum 97 – Steam to jacket 93 – Steam to chamber

273ºF / 310kPa

270ºF / ~ 210kPa

199 kPa

230ºF/ ~ 115kPa 100kPa

Condition to open T<230ºF ; P<115kPa

270ºF - 3min.

115kPa

Ex. Mode 1

50kPa 25kPa

0kPa

Start (Close door)

Door secure Temp. control Pres. control On (activated)

10 min

Page 29 of 117 pages

Page 35

Program 9 - for Liquids (Slow 250)

This program is intended for the sterilization of liquids in open or closed containers (but not sealed) and other goods, which its manufacturer declares their compliance to be sterilized in the following conditions:

♦ Sterilization temperature 250ºF ♦ Sterilization time: 15 mins. ♦ Slow discharge of the pressure.

Performance description: Residual air is displaced due to 3 vacuum pulses (down to 25 kPa) and 2

steam pulses up to 199 kPa. The 3rd vacuum pulse is followed with introducing saturated (controlled) steam into the chamber to the required sterilization temperature.

Slow exhaust stage is performed by discharging the pressure very slowly from the chamber. When the pressure reaches a level of 115 kPa the ejector is activated till a pressure drop to 25 kPa.

Pressure equilibration. To enable the door to be opened, air is introduced to the chamber through a microbiological filter till the equilibration with atmospheric pressure.

Note:

The temperature of the chamber must be below 203ºF and the pressure must be below 115 kPa to enable the door to be opened.

Page 30 of 117 pages

Page 36

Program: 9- Slow 250

Front door close Msw PT100 Drain Control 5 PT100 Condense 1 PT100 Condense 2 IMT Jacket IMT Chamber

Open front door Close front door

Ejector

Buzzer

13 – Cool drain 15 – Water to ejector 43 – Air inlet

73 – Fast exh 74 – Slow exh. 75 – Vacuum 97 – Steam to jacket 93 – Steam to chamber

273ºF / 310kPa

250ºF / ~ 210kPa

199 kPa

230ºF / ~ 115kPa 100kPa

250ºF 15min.

115kPa

Condition to open T<230ºF ; P<115kPa

Ex. Mode 4

50kPa 25kPa

0kPa

Start (Close door)

Door secure Temp. control Pres. control On (activated)

Page 31 of 117 pages

Page 37

Program 10 - for Liquids (Slow 250)

♦ Sterilization temperature 250ºF ♦ Sterilization time: 15 mins. ♦ Slow discharge of the pressure.

Performance description: Residual air is displaced due to 3 vacuum pulses (down to 25 kPa ) and 2

steam pulses up to 199 kPa . The 3rd vacuum pulse is followed with introducing saturated (controlled) steam into the chamber to the required sterilization temperature.

Slow exhaust stage is performed by discharging the pressure very slowly from the chamber. When the pressure reaches a level of 115 kPa the ejector is activated till a pressure drop to 25 kPa .

Pressure equilibration. To enable the door to be opened, air is introduced to the chamber through a microbiological filter till the equilibration with atmospheric pressure.

Note:

The temperature of the chamber must be below 203ºF and the pressure must be below 115 kPa to enable the door to be opened.

Page 32 of 117 pages

Page 38

Program: 10- Slow 250

Front door close Msw PT100 Drain Control 5 PT100 Condense 1 PT100 Condense 2 IMT Jacket IMT Chamber

Open front door Close front door

Ejector

Buzzer

13 – Cool drain 15 – Water to ejector 43 – Air inlet

73 – Fast exh 74 – Slow exh. 75 – Vacuum 97 – Steam to jacket 93 – Steam to chamber

273ºF / 310kPa

250ºF / ~ 210kPa

199 kPa

230ºF / ~ 115kPa 100kPa

250ºF 15 min.

115kPa

Condition to open T<230ºF ; P<115kPa

Ex. Mode 4

50kPa 25kPa

0kPa

Start (Close door)

Door secure Temp. control Pres. control On (activated)

Page 33 of 117 pages

Page 39

Program 11 & 12 - for Liquids (Slow 250)

♦ Sterilization temperature 250ºF ♦ Sterilization time: 15 mins.

Performance description: Residual air is displaced due to 3 vacuum pulses (down to 25 kPa) and 2

steam pulses up to 199 kPa. The 3rd vacuum pulse is followed with introducing saturated (controlled) steam into the chamber to the required sterilization temperature.

Sterilization period is controlled in such a way that the sterilization temperature will not drop below the required temperature, neither will increase by more than 37.4ºF. The saturated steam conditions are controlled in such a way that the fluctuation of pressure does not allow a drop below1kPa, neither an increase of 3 kPa above the high limit of the Ste. Temperature.

Slow exhaust stage is performed by discharging the pressure slowly from the chamber. When the pressure reaches a level of 115 kPa the ejector is activated till a pressure drop to 25 kPa.

Pressure equilibration. To enable the door to be opened, air is introduced to the chamber through a microbiological filter till the equilibration with atmospheric pressure.

Note:

The temperature of the chamber must be below 203ºF and the pressure must be below 115 kPa to enable the door to be opened.

Page 34 of 117 pages

Page 40

Program: 11 & 12 - Slow 250

;

Front door close Msw PT100 Drain Control 5 PT100 Condense 1 PT100 Condense 2 IMT Jacket IMT Chamber

Open door Close door

Ejector

Buzzer

13 – Cool drain 15 – Water to ejector 43 – Air inlet

73 – Fast exh 74 – Slow exh. 75 – Vacuum 97 – Steam to jacket 93 – Steam to chamber

273ºF / 310kPa

250ºF / ~ 210kPa

199 kPa

221ºF / ~ 115kPa 100kPa

Condition to open T<230ºF

P<115kPa

250ºF 15min.

50kPa 25kPa

0kPa

Start (Close door)

Door secure Temp. control Pres. control On (activated)

Page 35 of 117 pages

Page 41

Program 13 "Bowie & Dick Test”

This program is intended to test residual air in the chamber. The parameters are locked in such a way that they can not be changed. These are the parameters:

♦ Sterilization temperature 274ºF ♦ Sterilization time 3.5 mins. ♦ Drying period of 2 mins.

Performance description: Residual air is displaced due to 4 vacuum pulses (down to 25 kPa) and 3

steam pulses up to 199 kPa . The 4th vacuum pulse is followed with introducing saturated (controlled) steam into the chamber to the required sterilization temperature.

Sterilization period is controlled in such a way that the sterilization temperature will not drop belowthe required temperature, neither will increase by more than 37.4 ºF. The saturated steam conditions are controlled in such a way that the fluctuation of pressure does not allow a drop below1kPa, neither an increase of 3 kPa above the high limit of the Ste. Temperature.

Fast exhaust stage is performed by discharging rapidly the pressure from the chamber. When the pressure reaches a level of 115 kPa the vacuum pump is activated till a pressure drop to 25 kPa.

Drying is achieved by evacuating the vapor from the chamber in "under-pressure” phase along a period of 5 minutes.

Pressure equilibration. To enable the door to be opened, air is introduced to the chamber through a microbiological filter till the equilibration with atmospheric pressure.

Note:

The temperature of the chamber must be below 230ºF and the pressure must be below 115 kPa to enable the door to be opened.

Page 36 of 117 pages

Page 42

Program: 13- Bowie & Dick

;

Front door close Msw PT100 Drain Control 5 PT100 Condense 1 PT100 Condense 2 IMT Jacket IMT Chamber

Open door Close door

Ejector

Buzzer

13 – Cool drain 15 – Water to ejector 43 – Air inlet

73 – Fast exh 74 – Slow exh. 75 – Vacuum 97 – Steam to jacket 93 – Steam to chamber

273ºF / 310kPa

274ºF / ~ 210kPa

199 kPa

230ºF / ~ 115kPa 100kPa

Condition to open T<230ºF

P<115kPa

Ex. Mode 1

115kPa

50kPa 25kPa

0kPa

Start (Close door)

Door secure Temp. control Pres. control On (activated)

2 min

Page 37 of 117 pages

Page 43

Program 14 "Air leakage Test”

This program is intended to test air leakage to chamber through the door seal or any other seals. This test is performed in vacuum phase.

Performance description:

Vacuum is built up in the chamber down to 10kPa. At this stage all valves and motors are shut. A period of 5 minutes is counted to enable stabilization of pressure. During the next 10 minutes the pressure is monitored. The allowable change of pressure during these 10 minutes is 1.3kPa.

Page 38 of 117 pages

Page 44

Program: 14- Air leakage test

Front door close Msw PT100 Drain Control 5 PT100 Condense 1 PT100 Condense 2 IMT Jacket IMT Chamber

Open door Close door

Ejector

Buzzer

13 – Cool drain 15 – Water to ejector 43 – Air inlet

73 – Fast exh 74 – Slow exh. 75 – Vacuum 97 – Steam to jacket 93 – Steam to chamber

273ºF / 310kPa

250ºF / ~ 210kPa

199 kPa

230ºF / ~ 115kPa 100kPa

Condition to open T<230ºF ; P<115kPa

50kPa 25kPa

0kPa

Start (Close door)

Door secure Temp. control Pres. control On (activated)

5min. 10min.

Page 39 of 117 pages

Page 45

4. CONTROL AND MONITORING

Control Panel ‘CAT 2007’

Page 40 of 117 pages

Page 46

4.1 Description of panel 'CAT 2007'

The Operation Panel is composed of the following parts:

♦ 4 rows display, 20 characters in each row. ♦ 18 key pads ♦ 2 LED's (Fail, Run) ♦ 1 locking key

4.1.1 Keypad

STANDBY

The ON/ST.BY key is located on the top right side of the panel. Pressing the keypad lights up the operation panel. When there are 2 panels, both light up even though only one was pushed.

The 3 Command Keypads F1-3: Functions 1-3

F1 F2 F3

These keypads are found under the display. The function to be performed will be listed on the display above the keypad.

10 Digit keypads

These keypads are used for 2 purposes. In normal working conditions, the program option is used – pressing on the number keypad, for example no. 3 selects program 3. Under display mode, the keypads will be used as number keypads to enter a code or a number.

UP/DN Keypads

In normal working conditions they are used to browse through the different cycles. Under set-up mode they will change numeric values or cause the display to progress to the next screen.

START Keypad

When the autoclave is in Ready position, pressing on START key activates the cycle.

STOP

This key is active whilst the autoclave is in process. Pressing this key at any stage of the cycle stops operation.

Page 41 of 117 pages

Page 47

Canceling the FAIL message

At the end of an aborted process the FAIL light is turned on and an error message is displayed on the screen indicating the cause of the failure. Pressing the STOP key cancels the displayed message and switches off the FAIL light.

RUN/FAIL LED's

The operation panel contains 2 small LED's are located on the top left corner. The RUN LED (green) lights when the autoclave

is in process. When the system has been turned off at the ST.BY keypad, the RUN LED flashes for 1/2 a second for every 2 seconds showing there is still power entering the system (i.e. the appliance has not been switched off). The FAIL LED (red) lights when there is a problem with the system.

Page 42 of 117 pages

Page 48

4.1.2 Display

The CAT2007 display consists of 4 alphanumeric rows with 20 characters in each row:

First Row

First 3 characters define the Cycle no. (ranges from 1-14) There are 8 characters to define the Cycle name. The final 5 characters at the right of the row are allocated to displaying the status of the appliance or the stage in which the cycle is found whilst running.

♦ When the autoclave is in waiting stage – ST.BY ♦ When the autoclave is ready to work – READY ♦ When a process ends correctly – END ♦ When a program ends incorrectly – FAIL

The names of the stages follow:

♦ Vacuum ♦ Exh. (Exhaust) ♦ Heat ♦ Dry ♦ Ster. (sterilization) ♦ Test

Following are the 14 cycles, names and relevant temperatures:

Cycle no. Program Temp. ºF 010203 &4 0506070809091011 & 1213 14-

Second Row:

This row displays the temperature in the chamber, pressure in the chamber, and jacket pressure.

Third Row:

This row is used to display messages to the operator such as DOOR1 OPEN.

Unwrapped 250 Unwrapped 250 Unwrapped 270/274 Wrapped 270 Wrapped 270 Wrapped 274 Wrapped 270 Liquids 250 Liquids 250 Liquids 250 Liquids 250 B&D test Leak test

Page 43 of 117 pages

Page 49

Fourth Row:

In the bottom row the names of the commanding keypads appear. Under the display there are three keypads without symbols or names These keypads receive their commands by the name that appears above them in the 4th row of the display. During a cycle, the fourth row is used to display the timers, such as STE Time 02:25, or during prevacuum, to display the stage of the pulse, such as puls1 – pump to 21K.

Page 44 of 117 pages

Page 50

4.2 Description of Displayed Messages and Safety Measures

03 – Manual Stop

100 – Man.Stop

05-Door Unlock

06-Temp. Error

07- Low Heat

08- Low Temp.

09- High Temp.

10- Low Pres.

11-High Pres.

12-Low Vacuum

13 – Jacket not Ready

21 – Door1 Safe Switch

23 – Door1 Gasket Low

Vacuum

Message is displayed and the FAIL indicator lights after the STOP key is pressed for more than 1 second during the cycle (excluding the drying stage). This message is displayed and the FAIL indicator lights after the STOP key is pressed for longer than one second in the drying stage. Message is displayed if either of the following occurs: The START button is pressed and the door is not closed; If during a cycle for eg. the pressure drops in the gasket. If the temperature sensor disconnects for any reason during the heating stage. Indications that there is a disconnection are if the read temperature is either higher than 140ºC or lower than 5ºC. Message is displayed and sterilization does not start if the autoclave has not reached sterilization temperature after heating for the maximum time as defined in the HEAT T.O. parameter. Message is displayed, fail indicator lights and cycle is aborted, if the temperature drops for more than 5 secs. below the required sterilization temperature. Message is displayed, fail indicator lights and program is aborted: If the temperature rises 37.4ºF above the required sterilization temperature during the sterilization cycle. Message is displayed, fail indicator lights, and the program is aborted if the pressure drops for more than 5 secs. below the pressure correlated to the required sterilization pressure. This message is displayed, fail indicator lights, and the program is aborted, if pressure rises above the pressure correlated to the sterilization temperature plus +37.4ºF- for more than 5 secs. This message is displayed if after 18 mins. the system has not reached VacDip1or VacDip2 values during the prevacuum stage. It also appears if the Leak Test program fails. This message is displayed if the START key was activated before the jacket reached the desired pressure. If whilst opening door1 of an automatic sliding door the door1

switch closes, the door will open and this message will appear. If whilst opening Door1, you do not achieve the proper vacuum in Gasket1.

Page 45 of 117 pages

Page 51

25 – Vac Res. Empty

27 – First Close Door

If during the prevacuum stage, drying stage, vac. test or leak test it is revealed that the lower float switch in the vacuum water reservoir is open for more than 1 second (so there is no water entering the water reservoir and the pump has therefore been closed to protect it).i.e. Vfloat –L = “1”

This message appears if there was an attempt to perform IN/OUT Test whilst the door was open.

190 – Water Too High

Informative Messages

Calibration

Closing Door Wait

Open Door Wait

Door1 Open

This message appears when the level of water in the chamber is too high. The chamber float switch detects the water level and in case it’s too high closes all the valves and the FAIL indicator lights.

This message appears automatically on panel 2 during calibration.

Whilst an automatic door is closing, this message is displayed in order that the operator will wait until the closing operation of the automatic door ends.

Whilst an automatic door is opening, this message is displayed in order that the operator will wait until the opening operation of the automatic door ends. This message appears when Door1 is open. It will also appear if the door is supposedly closed but there is not enough pressure in the gasket to seal it properly.

Under Test

This message appears on panel 2 during the IN/OUT Test and during SetUp.

Page 46 of 117 pages

Page 52

4.3 Operating the Control Panel

4.3.1 Starting up the System

After turning on the system, the following screen is displayed for a few seconds:

After a few seconds the Stand By screen is displayed.

This is the central screen from which all operations can be performed. It is also the “Ready” screen from where cycles can be started when all the relevant conditions are fulfilled. If the system is ready the display appears as follows:

If the system is not ready it will not allow you to start the cycle. If, for example, Door1 is open when the system is turned on, the display will warn the operator of this in the 3rd row of the display allocated to messages, and the screen will appear as follows:

The 3 command keys in the Stand By screen are:

Above the left keypad (F1) Show Above the middle keypad (F2) Option Above the right keypad (F3) Open

Page 47 of 117 pages

Page 53

4.3.2 Selecting a Cycle

A cycle can only be selected during Stand By from the Stand By / Ready screen which displays the cycle number and name in the top row.

A cycle can be selected as follows:

♦ Press the UP/DN keypad to change the cycle where pressing UP moves to

the next program and pressing DOWN moves to the previous program.

♦ Press on a number. When pressing on keypad 4 the chosen program will be

number 4, and so on.

Selecting a 2 digit cycle:

When 2 numbers are pressed within 2 seconds of each other, then both the numbers define the program number (when the program number is 10 or above). For example; to chose program 12, number 1 must be pressed, and within 2 seconds number 2 must be pressed.

Show Parameters

After selecting the cycle, pressing the SHOW command key presents the following screen:

where the message displayed in the 3rd row describes the following:

♦ the temperature; the sterilization temperature ♦ the time; the sterilization time

♦ D-Time; drying time. This screen is displayed for 10 seconds after which it automatically returns to the ST.BY screen. This command key is not active for cycle 14 – Leak Test. Once the following conditions have been fulfilled,

♦ There is enough steam pressure in the jacket. ♦ Enough air pressure for the pneumatic valves (option). ♦ Doors closed. ♦ Enough water pressure for cooling (option). ♦ Enough water in the water reservoir.

Page 48 of 117 pages

Page 54

the SETUP has been checked and the display is in the ST.BY /Ready mode, press START to run the cycle: The RUN LED lights and the cycle is in progress. After this, LED's switch off and the appliance is in Stand By or RUN program (depending on if the power turned off at the last time in order to run a program).

Power On Reset Test

1. Turn on the appliance

2. Be sure that all the valves and outputs, including LED's on the panel, are turned off.

3. Be sure the last illumination of the panels is turned on.

4. Be sure the message – Wait !!!

Version = (version name)

5. Appears on the 2 panels with the correct version.

7. Be sure that 2 LED's in each panel are turned off, the message deleted and the

system passes to the Stand By stage.

In/Out Test – Design:

The system contains a stage called In/Out Test Stage. This includes all the required elements for the In/Out Test. The test includes:

1. Testing all the outputs. Each time only one output is turned on. The output passes to ‘ON’ for a maximum time of 15 seconds or until the UP keypad is pressed. The command begins from output number 1 until 24.

2. Testing of all the digital inputs should take a maximum time of 15 seconds for each input. When the input is found in “0” it will show ‘ON’ on the screen. When the input is in “1”, it will show ‘OFF’ on the screen.

3. All the analog inputs will be displayed on the screen without a filter. As such it will be able to calibrate them at the time that the display is on the screen via. the computer.

4. At the end of the stage, it will allow the In/Out Test to start afresh or to exit. When exit is chosen, the system will initialize from new.

5. Inputs for the In/Out Test require a code.

Testing the In/Out Routine

1. Turn on the system.

2. Press the OPTION keypad. The right command keypad will be called InOut. By pressing on this key, the screen displays: Code: Enter InOut Test Code: Enter the code 2ØØ7. The screen will display the message ‘Digital Ø1 On!!!’. Be sure that OUTØ1 is on. Press on ‘UP’. The screen will display the message ‘Digital OUTØ2 on!!!’. Be sure that OUTØ2 is on.

Page 49 of 117 pages

Page 55

4.3.3 System Set-Up (changing parameters and values)

Note:

♦ The system allows 15 seconds for values to be entered. If this time passes

and the panel has not been touched, the display will move on automatically to the next screen.

♦ When codes are not entered within the 15 seconds, the RUN and FAIL lamps

light and the display return to WAIT and then the Stand BY screen. ♦ If the code is incorrect the above will also occur. ♦ When the display shows ØØØØ and a single value (i.e. between 1-9) is to be

entered, the Ø must first be pressed. The single value can not be entered on

its own, for example, to enter the number 4, the value is entered by pressing

the Ø three times and then the number 4. ♦ When a value is to be entered, the right command keypad is Enter:

 If the value is entered via the digit keypad, after the final digit is entered,

the system automatically transfers to the next screen, and Enter need not be pressed.

 If the value is entered using the UP/DN arrows, the Enter keypad must always

be pressed to progress to the next screen.

The system setup includes the following functions:

Clock – Date and Time, Language, Doors Number, Door Type & Atmospheric Pressure

To check the system has been set up correctly, press the OPTION keypad in the ST.BY screen. The screen displayed is as follows:

Press the SETUP keypad. The system requests a code.

Enter the code and the display automatically moves on to the next screen after the last digit is entered.

Clock

The clock first displays the date and then the time.

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Date

The date is always displayed as day/month/year.

Press the UP/DN keys to change the value.

1. Press ENTER (the right command keypad), after selecting the desired value to move on to the next value, i.e. the 'day value' will be underlined.

2. Press the UP/DN keypad to change the value and ENTER. The 'month value' will be underlined and the process continues.

3. To change the Year value to ØØ, keep pressing the DOWN key until you get to Ø, press ENTER.

If no changes are to be made, then continue pressing ENTER to skip to the next step. After the year value, when ENTER is pressed the display changes to the Time display.

Time

Time is always displayed in hour/min/sec. When entering the screen, the hour value is underlined. Press the UP/DN key to change this value. Press ENTER (the right command key), to move on to the 'minute value'. Continue the process until the time is correct. If no changes are to be made, press ENTER to move on to the 'minute value'. Pressing ENTER after the second value has been changed automatically skips to the next screen – the Language screen. If there were no changes to be made, continue pressing ENTER until the Language screen is displayed.

Language (Option)

4 popular languages have been specified with Latin letters only: English, German, French and Spanish. This screen is only applicable if using different languages. The right command key will be ENTER. If English is being used, leave the code at Ø and press ENTER to move on to the next screen – Doors Number. If the language requires changing, press the appropriate number from the choice below and then press ENTER.

English German French Spanish

Ø 1 2 3

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Doors Number

After entering the language, the display is as follows:

The options for this autoclave having one door, no key has to be selected. Press ENTER, and the system moves on to the next screen.

Door Type

There are 3 different door types for autoclaves – Manual Door, Hinged Automatic Door, or Sliding Automatic Door. In this case the door is automatic, just press ENTER as this is the option already displayed (ØØØ1). Enter these values either through the UP/DN keys and then press ENTER, or physically enter the digits whereby the screen will automatically progress to the next display after entering the fourth digit.

Atmospheric Pressure

The atmospheric pressure at Sea Level is 100kPa. For every 100m above sea level, the atmospheric pressure drops 1kPa, and for every 100m below sea level, the atmospheric pressure increases 1kPa. If pressure is set correctly, press ENTER and the next screen appears. If pressure needs to be altered, this may be done either through the digit keypad or the UP/DN keypads.

Jacket (Jacket Type)

If there is no Jacket, then press Enter. If there is a Jacket, then via the UP/Dn keypads, choose the correct number according to the following conditions:

♦ 1-There is a Jacket – the steam to the chamber passes from the jacket ♦ 2-There is a Jacket – the steam to the chamber passes directly and not via

the Jacket. Press 2 for this autoclave.

♦ 3-There is a Jacket and it is divided without a separation from the steam

generator, and the steam passes via the jacket to the chamber.

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F. O. Mode

This mode enables F.O. calculations, the processing being based on data fed by two temperature sensors one mounted in the chamber, one on the condensate pipeline. The F.O. calculation is performed for cycles with Ster. Temp. in the range of 215ºF - 273ºF, especially used in Programs 9-12. F.O. = 0 (unable), F.O. 1= total heating time + total cycle time + cooling time. F.O. 2 = compensates the difference between heating time,cooling time and exhaust. Calculates using factor 1.5 of the total accumulated heating and cooling time and converts that into the equivalent sterilization time. Temp. F.O. = Determines the temp. at which F.O. calculations should begin.

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4.3.4 Changing Cycle Parameters

The screen that allows for parametric changes appears as follows: Pressing Clear or Enter before entering the code returns to the Stand By screen, and the RUN & FAIL LED's are lit. Enter the correct code only via the UP/DN keypads, press ENTER to proceed to the next screen. Pressing the UP/DN keypads can also change all parameter values.

Cycle Setup Parameters:

Code 1 or 11 Parameters

STE Temp – Required sterilization temperature for the process

Entry code Resolution Minimum value Maximum value

STE Time – Required sterilization time for the process Entry code Resolution Minimum value Maximum value

Dry Time – Required drying time for the process: Entry code Resolution Minimum value Maximum value

Heat T.O. – Maximum time for heating the chamber for starting sterilization

When the duration of the heating stage is longer than Heat T.O., the program will collapse with the message ‘Low Heat’.

Entry code Resolution Minimum value Maximum value

1 or 11 34ºF 221ºF 280ºF

1 or 11 1 minute Ø minutes 59 minutes

11 10 seconds 1200 seconds (20 minutes) 3600 seconds (minutes)

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Ex Mode – The method for exhausting the steam at the end of the process Ex Mode Fast Ex N.A. Slow Ex. (waste) Slow Ex. (liquids) Cooling with compressed air Cooling with water circulation

EndTemp – Ending Temperature (Exhaust Stage)

Defines the temperature at which the process ends for opening the door.

Entry code Resolution Minimum value Maximum value

PulsNum. – No. of pulses in the prevacuum stage Entry code Resolution Minimum value Maximum value

11 34ºF 104ºF 279ºF

11 1 1 5

1 2 3 4 5 6

VacDip1 – Vacuum value in the first pulse

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

Entry code Resolution Minimum value Maximum value

VacDip2 – Vacuum value in the remaining pulses

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

Entry code Resolution

Minimum value Maximum value

VacTime1 – Waiting time in the first pulse

In the prevacuum stage, in the first pulse after reaching VacDip1, there is a waiting time known as VacTime1 (in seconds). This delay occurs so vacuuming can continue.

Entry code Resolution

Minimum value Maximum value

11 1 kPa 1 kPa 75 kPa

11 1kPa

1kPa 75kPa

11 1 second

3 seconds 1800 seconds (30 minutes)

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VacTime2 – Waiting time for the remaining pulses

In the remaining pulses (not pulse no.1) in the prevacuum stage, after reaching VacDip2 stage there is a time delay known as VacTime2 (in seconds).

Entry code Resolution

Minimum value Maximum value

Wtr Time – Time for entering the water into the generator after the autoclave is touching the water

This value defines in seconds the time that the water pump continues working and entering water to the steam generator after the upper electrode touches water, to prevent a situation wherein immediately after the electrode touches water the pump immediately begins operation.

Entry code Minimum value

Maximum value

LimitP add – Adding pressure to the maximum pressure

This value defines addition to the maximum pressure that is computed to the jacket control. For example: When the desired temperature is 273ºF, the maximum temperature maintained in the jacket will be adjusted to a temperature of 137ºC (i.e. 332kPa) When this pressure is not enough, it can be increased by changing the value of the LimitP add. If the parameter value remains Ø, the maximum pressure in the jacket will be 332kPa, however if this value will be 10, the maximum pressure will be 342kPa.

Entry code Resolution

Minimum value Maximum value

11 1 second

1 second 1800 seconds (30 minutes)

11 Ø second

90 seconds

11 1 kPa

ØkPa

30 kPa

Calib Code:

This parameter is used to set the calibration code.

Entry code Resolution

Minimum value Maximum value

Puls Pres1 – The pressure in pulse no.1 in the prevacuum stage

This defines the first pulse pressure in the prevacuum stage. If it is defined as 100kPa, the system will not enter steam into the chamber, however the vacuum pump will immediately operate to create a vacuum. If the value is defined over 100kPa, the system will open the steam valve to the chamber until the desired pressure is reached.

Entry code Resolution

Minimum value Maximum value

11 1

255

11 1kPa

100 kPa

200 kPa

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Puls pres2 – The pressure in pulse 2 and onwards in the prevacuum stage

After the completion of pulse no.1, the system will enter steam by the defined value in puls press.

Entry code Resolution

Minimum value Maximum value

Stay Time - Waiting time between heating and sterilization

This parameter allows partial entry into the sterilization stage with a reduction of overshoot and the reduction difference between the different sensors that are entered into the chamber for control or validation. In the heating stage the system stops heating before entering sterilization according to the STAY TIME value. When this value is 2 minutes, the system stops at 35.6ºF before entering sterilization and will proceed at a rate of

33.80 ºF/min during the STAY TIME.

Entry code Resolution

Minimum value Maximum value

This is the final parameter under Code 11. After pressing ENTER the display will return to the ST.BY screen

11 1 kPa

100 kPa

200 kPa

11 1 min.

Ø min.

10 min.

Dry Vac. - Dry Vac. =0 ; Vacuum pump works continuously. Dry Vac. = 5; Vacuum pump works for 5 mins. after which air is introduced for 30 secs. of ON- and 30 secs. OFF intervals (depending on the interval selected by the operator).

Entry code Resolution

Minimum value Maximum value

Code 13 Parameters: ReqPrs+ - The addition to the required pressure for sterilization

This parameter allows the pressure point that will be maintained during the sterilization stage to be set in the following manner: If the desired temperature is 273ºF, the required pressure (from the tables) is 305kPa. When the ReqPrs+ is Ø, the system will be maintained at 305kpa during the sterilization stage. When the ReqPrs + equals 5kPa, the system will be maintained at 310kPa in the sterilization stage. It is advised to work with a value of 7kPa.

Entry code Resolution

Minimum value Maximum value

11 1 min.

13 1 kPa

20 kPa

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F.O. Temp Mode

Determines the temperature F.O. calculations will begin.

Entry code Resolution

Minimum value Maximum value

Select PT100

There are 3 sensors that regulate cycles – one for condense, one in the chamber, and one in drain control output. Selections:

1. Sensor on the condense line x 2 (dual). (2)

2. Sensor in the chamber (1)

3. Sensor for drain control (5).

If sensor number 2 is not connected (faulty), the system will automatically work with sensor no.1 (the sensor in the condenser), even if 2 was selected, as 2 is only an option. This is the final parameter under Code 13. Pressing ENTER; the display returns to the ST.BY screen.

13 1

215

273

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4.3.5 Test Programs

To arrive at this option, return to the ST.BY screen and press the OPTION Keypad (the middle command keypad). Then screen will appear as with SETUP and Calibration. The word above the right command keypad will be INOUT. Press the right keypad you will be asked to enter a code. Via the numeric keypad, enter the correct code. The display will automatically move on to the next screen after entering the final digit. The screen will appear as follows:

Every 15 seconds the Digital Out number will automatically increase by one until it reaches Digital Out21. It then automatically passes on to the next screen. Pressing the UP keypad will also progress through the Digital Out values. The next screen to appear is the following:

The screen will display the message ‘Electrd – h # #’. # # is a number value. When the electrode touches water the value will be small, from 80 down to 0 when the water is high in electric molecules. When the electrode is in the air (not touching water) the value will be higher than 80 up to 99. This electrode is located in the generator so that if there is no water in the generator the value is said to be 99 (greater than 80). This electrode is the highest electrode in the generator. Press on ‘UP’ to move to the next stage, or wait 15 seconds and it will do so automatically.

The next screen to appear will display the message ‘Electrd – L ##’, with ## being a number value. When the electrode touches water the value will be small, from 80 down to 0 when the water is high in electric molecules. When the electrode is in the air (not touching water) the value will be higher than 80 up to 99. This electrode is located in the generator so that if there is water in the generator the value is said to be 0 (lower than 80). This electrode is the lowest electrode in the generator. Press on ‘UP’ to move to the next stage, or wait 15 seconds and it will do so automatically.

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The next screen will appear as such

Where: T1 – T4 display the temperature received from T1 until T4 (without a filter). D1 – Displays the pressure in gasket 1 Gen – Displays the pressure in the generator. In this stage you have to calibrate the displayed sensors.

Press on ‘UP’ to move to the next stage, or wait 15 seconds and it will do so automatically.

The next screen to appear refers to the digital inputs. As with the digital outputs, it will progress to the next value automatically after 15 seconds, or by pressing the UP key. Values 5 & 7 – 11 will be OFF.

The final screen to appear in the INOUT test gives 2 options: Pressing UP will return to the Code Entry screen for the INOUT Test. Pressing STOP will return the display to the ST.BY screen.

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4.3.6 Display Function (applicable only for automatic doors)

Display when Open or Closing the Doors

Opening an Automatic Door

During the process of opening an automatic door, the message OPENING DOOR – WAIT will appear in the 3rd row.

Closing an Automatic Door

During the process of closing an automatic door, the message CLOSING DOOR – WAIT will appear in the 3rd row.

If the pressure in the chamber is higher than 115 kPa, it will not be possible to open the door.

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4.3.7 Display during a cycle

Display during the Pre-Vacuum stage

When the cycle passes to the Heat stage the steam enters the system, in place of ‘PUMP TO 25K’, it will display ‘HEAT TO 160K’. When the cycle then passes to the Exhaust stage, in place of ‘HEAT TO 160K’, it will display ‘EXH TO 100K’.

Display during the heating stage

Display during the sterilization stage

Display during the Drying Stage

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Help:

If at any stage there is a problem, the system can be turned off at the power switch. Turn on the power again, whilst at the same time pressing the STOP keypad until you hear a long buzz. After the Loading screen, the screen lights with the message below. The display returns to the ST.BY screen and you can continue from there.

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5. CALIBRATION

The calibration of temperature and pressure is performed digitally. The temperature and pressure measuring circuits, are designed with components having a 1% precision. The temperature circuit is linear and has an output of 100mV-2400mV for a temperature range 68ºF-305ºF. The pressure circuit is also linear and has an output of 100mV-2400mV for a pressure range 0-400kPa. The measuring at the A/D is void for values higher than 2400mV or lower than 100mV. It is clear that even though the precision of the components of the circuit is 1%, the accumulated error can reach ± 5%, therefore calibration is necessary. The system is provided, with non-erasable memory in which the offset and gain data of the sensors are stored.

This data may be input to the system, through programming or through the autoclave. In this chapter we shall describe the calibration of temperature and pressure through the autoclave, the programming calibration procedure is altogether identical.

Definition of Gain and Offset:

Every straight line can be defined by the equation ax+b=y. “a” is the deviation from y=0 and “b” is the slope of the line. In our case a=Gain and b=Offset. The system is based on calculation of offset and gain of two points as in the following example. If the actual measured pressures are 100 kPa & 300 kPa and the displayed pressures are 90 kPa & 310 kPa respectively, the ‘input Vs pressure” graph will be as follows.

READ

310

100

PRESURE

INPUT FROM SENSOR

ACTUAL

The calibration method enables to introduce these data into the system in order to perform the automatic correction of the OFFSET and GAIN. It is recommendable to find the two points which have to be input to the system, before performing the calibration.

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5.1 CALIBRATING TEMPERATURE & PRESSURE

Return to the ST.BY screen and select the OPTION command keypad. Above the middle command key the word CALIB is displayed. Press the middle keypad and the same screen for entering the SETUP code will appear.

Enter the correct code via the digit keypad and the system begins displaying the calibration options. Note:

♦ If the code is not entered within 15 seconds, the display returns to the

Stand BY screen. ♦ If the code is incorrect it will return to the ST.BY screen ♦ In all screens following the code entry screen, the middle command

keypad is Clear and the right keypad is Enter. Pressing on either of these

keys takes you to the next screen. ♦ The values in all the following screens can only be changed via the

UP/DN keypads. Once the correct value appears, press Enter and the

system will progress to the next screen.

The screens appearing after the entry code screen for Calibration are as follows:

5.1.1 Temp 1:

Temperature of sensor 1 on the condense line. This screen requests a code to be entered. Press the UP key once, to enter the code value ØØ1 and press ENTER. This will provide the screen giving 4 temperature values:

A100 R100 A130 R130

Pressing the far right command key (F3) allows you to move to the different values, which may be changed using the UP/DN key only. After F3 is pressed when it is on the last value, it will move to the next screen. Pressing the middle command key (F2) will read the value of the sensor. Pressing STOP will stop the cycle.

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5.1.2 Temp 2:

Temperature of sensor 2 on the condense line.

Refer to Temp1 for instructions.

5.1.3 Temp 3 (Option):

Temperature of sensor 1.

Refer to Temp1 for instructions.

5.1.4 Temp 4 (Option):

Temperature of sensor 2.

Refer to Temp1 for instructions.

Temp 5 - For drain control output Temperature of sensor 5.

Refer to Temp1 for instructions.

5.1.5 Chm Pres: (Chamber Pressure)

This screen requests a code to be entered. Press the UP key once, to enter the value ØØ1 and press ENTER. This provides the screen giving 4 pressure values:

A100 R100 A300 R300

Pressing the far right command key (F3) allows you to pass to the different values, which may be changed using the UP/DN key only. After F3 is pressed when it is on the last value, it moves on to the next screen. Pressing the middle command key (F2) reads the value of the sensor. Pressing STOP will stop the cycle.

5.1.6 Jkt Pres: (Jacket Pressure)

Jacket Pressure.

Refer to Chm Prs for instructions.

5.1.7 Gen Pres:

Generator Pressure.

Refer to Chm Prs for instructions.

5.1.8 D1 Pres:

Pressure in Gasket1.

Refer to Chm Prs for instructions.

After Enter is pressed, the Calibration options are concluded and the display returns to the ST.BY screen. This calibration method enables the technician to change a certain point without affecting a second point. E.g.: When we work at 273ºF and at 250ºF and during the temperature

checking for 273ºF, the thermocouple introduced in the chamber indicates the actual temperature 270ºF; when we work at 250ºF the thermocouple indicates the actual temperature in the chamber 250ºF.

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We are interested in correcting the measured temperature for 273ºF without changing the temperature at 250ºF which is accurate. Considering the above example, setting data can be done as follows:

Upper Row A 140º F R 141ºF

A 266º F R 266ºF

The system calibrates the new offset and gain and loads them into the non-erasable memory. As a result, while running a 273ºF program the correction is automatically

done, while at 250ºF no change is felt.

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6. TRANSPORTATION OF THE AUTOCLAVE

To facilitate transporting the autoclave through narrow passageways, the cabinet is made in two sections. After transporting the autoclave to its destination reassemble.

1. Remove all the bolts which tighten the control panel with the autoclave panel (2,3).

2. Remove the bolts that tighten the control base to the autoclave base (1).

3. Disconnect the multi-pins connector mounted on the main electric box.

4. Separate the two autoclave parts.

After the autoclave has been installed at the desired location, connect the two parts according to the reverse order of the directions given for dismantling.

Top View

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7. PREPARATION BEFORE STERILIZATION

Instruments to be sterilized must be clean, free from any residual matter, such as debris, blood, pads or any other material. Such substances may cause damage to the contents being sterilized and to the sterilizer.

1. Wash instruments immediately after use, to dispose of any residue.

2. Follow manufacturer's instructions on the use of products for cleaning and lubricating instruments after using the ultrasonic cleaner.

3. Before placing an instrument into the sterilizer tray, make sure that the instruments which are not of the same metal (stainless steel, carbon steel, etc.) are separated and placed in different trays.

Note: Check manufacturer's instructions for sterilization of each item.

4. In case of carbon steel instruments are used with stainless steel trays, the tray should be lined with a towel or paperwrap before placing the instrument. There should be no direct contact between the carbon steel and the stainless steel trays.

5. All instruments must be sterilized in an open position.

6. Place a sterilization indicator strip in each tray.

7. Once a week use a biological spore test indicator in any load to ensure sterilization.

8. Make sure that all the instruments remain apart during the sterilization cycle.

9. Empty canisters should be placed upside-down in order to prevent accumulation of water.

10. Do not overload sterilizer trays. Overloading will cause inadequate sterilization and drying.

11. Allow a distance of approximately 1" between trays to permit circulation of steam.

12. Wrapped instruments should be packed in material which promotes drying, such as autoclave bag, autoclave paper, muslin towels.

NOTE: Verify that the packaging method is in accordance with Good Practice approach and the packaging materials are in accordance with the applicable standards (e.g. EN868 series).

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The following is recommended:

Tubing

Rinse tubing after cleaning with pyrogen free water. When placing in tray, ensure that both ends are open, without sharp bends or twists.

Packs

Place packs upright on trays, side by side. Packs should not touch the chamber walls.

Sterilization of Liquids

Use only heat-proof glass, filled 2/3 full. Ensure that the glass container is covered but not sealed to prevent pressure build-up.

Every machine is supplied either with two stainless steel shelves, or with loading car and carriage.

The loading car is made of stainless steel and comes with adjustable shelves. It is designed to slide smoothly off the carriage into the sterilization chamber.

The carriage moves on four heavy - duty castors, which are mounted on its base.

When loading the materials to be sterilized into the chamber, observe the rules described in this chapter.

Do not overload the car or the trays as this can have adverse effects on the results of the sterilization and drying programmes.

Leave space between the packs or wrapped instruments to allow complete removal of air pockets in the conditioning stage, and for free circulation of steam in the heating and sterilization stages.

Unloading

On completion of the cycle, take out the load immediately from the sterilizer. Do not remove the load from the tray until its temperature reduces to the room temperature.

Let the load cool down in an area without air movement (air conditioning, etc.) and with minimum people passing by to avoid possibility of touching the hot load. Do not touch the hot load since hot load absorbs moister and, therefor, may absorb bacteria from your hand. Do not transfer hot load to metal shelves for cooling. Perform a visual inspection to ascertain that sterilizing indicators have made the required colour change, and that the load is dry.

The load shall be rejected if:

a. The package has been compressed.

b. The package is torn.

c. The load is suspected to be wet.

d. The load fell on the floor.

e. Condensed drops can be detected on the load.

During loading and unloading use safety gloves and glasses in accordance with local safety regulations and good practice.

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8. INSTALLATION INSTRUCTIONS

Only qualified and authorized personnel are allowed to install, check, test, maintain and serve the autoclave.

Mounting

♦ Check after unpacking the autoclave that the Serial Number (S/N) on its

nameplate corresponds with the package number.

♦ Place the autoclave on a level surface, leaving adequate space around it

for operation and service requirements. (see also the drawings)

♦ The ambient temperature around the autoclave should not exceed 104ºF,

80% humidity and the room must be ventilated 10 air changes/hour.

♦ Do not use the autoclave in presence of dangerous gases and vapors.

Utilities

Connect the autoclave to the utility supplies as follows:

Air

♦ Connect the air connector on the autoclave to the building air source by

means of a 1/2” pipe at 90 to 120 psi (6 to 8bar)

♦ If there is no external air source, use a small, independent air

compressor.

Mineral Free Water

♦ Connect the water reservoir container to a free mineral water supply

source by a 1/4".

See also the Water Quality chapter!

Tap Water

♦ The autoclave should be supplied with tap water; its hardness should not

exceed 0.7-2mmol/l. See also 2.5 Water Quality.

♦ The tap water pressure should be between 2 to 4 bar (30 to 60 psi).

♦ Connect the feed water to the network by a 1/2” pipe.

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Drain

Connect the following outlets directly to a drain funnel. Or connect them

through a drain collector pipe of 2” that should be covered. The drain system

should be vented.

♦ The exhaust from the chamber by a 1” pipe.

♦ The drain-cooling by a 1/2” pipe.

♦ The condensate from jacket by a 3/4" pipe.

♦ The discharge from ejector by a 1" pipe.

♦ The steam generator drainage by a 3/4‘’ pipe.

Power connection

♦ Connect the power cord, one phase, Neutral and Grounding to the

terminals in the electrical box and the ground wire- GND to the grounding

screw connection.

♦ The power outlet for the electrical supply is, 115 V/ 60 Hz.

Preliminary Checks

After installation and prior to putting the machine into operation, the following preparation and checks should be followed:

♦ Check the water and drain inlets are connected correctly to the utilities

and the manual taps on the external lines and the autoclave piping, are open.

♦ Check the manual bypass screws (on the base of the pilot solenoid

valves) are set in neutral position, i.e. the slit on the head of the screw is set in horizontal position.

♦ Search for leakage and fix piping joints if necessary.

♦ Check feed water pressure at the autoclave inlet complies with the

requirements.

♦ Check the electrical network switchboard if the autoclave circuit is

switched on, and fuses or circuit breakers are not interrupted, also checking if the correct voltage is present in the autoclave control box according to specifications.

♦ Check the circuit breakers in the control box are switched on.

If the results of the above checks are positive, the autoclave is ready for operation.

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9. OPERATING INSTRUCTIONS

For identification of push buttons, LED’s and valves refer to the next page:

1. Open the free-mineral water manual valve, to fill the water reservoir of the generator.

2. Open the feed water, manual valve for the vacuum pump supply and the drain cooling.

3. Open the manual valve of the compressed air inlet and set the air pressure at 6 bars.

4. Ensure the autoclave is powered by switching on the main switch located on the wall.

5. Watch the jacket pressure gauge, indicating the rising of steam pressure in the jacket. When the jacket pressure reaches 2.4 bars the sterilization cycle can be started.

Open the door by pressing the F3 function key located below the display, while the word OPEN appears on the lower row of the screen, above the F3 key indicating that the door can be open.

The message OPENING DOOR – WAIT is displayed in the third row. The door slides down to the lowest position.

Load the sterilizer, keeping in mind the recommendations of Chapter 7 in the operator’s manual on ‘Preparation before Sterilization’.

Note:

Selecting a program, setting the parameters and the operation modes can be done by the maintenance technician by setting the locking key in pos. OPEN and entering a code.

7. Close the door by pressing the F3 function key, when the word CLOSE appears in the lower row of the screen, above the F3 key. The door is lifted until being locked and the chamber is sealed. While the door is closing the message CLOSING DOOR – WAIT is displayed in the third row and the word READY appears in the first row, indicating autoclave is ready to start operation and the LED above the control panel is lit.

8. Select a sterilization program and press the START key, to operate the cycle. The entire sterilization process automatically proceeds. The LED RUN on the control panel is lit.

9. At the end of the cycle a buzzer sounds continuously, and the word END is displayed. Open the door by pressing the F3 function key while OPEN is displayed above this key. Press the STOP key to cancel the alarm.

Note: In case of failed cycle or manual stop by operator, the two LED's RUN and FAIL are lit. The reason for failure is displayed on the screen.

10. Take out the sterilized material from the chamber following the steps indicated in the ‘Unloading’ paragraph.

The sterility of instruments processed in unwrapped cycles cannot be maintained if exposed to non-sterile environment.

At the end of the day it is mandatory to close the feed-water and mineral-free water taps.

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Control Panel Assembly

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10. PRINTER

10.1 Printer Operation

The autoclave is equipped with a character printer, which prints a detailed history of each cycle performed by the instrument (for the record or for subsequent consideration).

The printing is made on thermal paper with 24 characters per line and contains the following information:

♦ Software version (is printed only on Power Dn)

♦ Real time

♦ Selected program

♦ Sterilization pressure

♦ Sterilization temperature

♦ Sterilization time

♦ Summary of performed cycle and identification hints.

When the sterilization cycle begins the printer starts printing the above data.

After the preliminary printing, the autoclave starts performing the sequence of operations of the cycle. The measured values of temperature and pressure are printed at fixed time intervals, according to the phase of the process, as shown in the table below.

The data is printed from the bottom up, beginning with the date and ending with “O.K.” for a complete cycle or “FAIL” for an aborted cycle.

For an example of a typical printout, see next page.

Page 75 of 117 pages

Page 81

PRINTER OUTPUT DESCRIPTION

Autoclave: 2301006 Autoclave serial no.

Name : __-------- Name of the operator to be filled in .

Load #: 0030 Useful to determine when to clean the autoclave.

To be filled in manually by the operator.

14/01/2003 13:45:16 Date and time the cycle ended

E13: 31 099.7ºC 049.5k The time, temperature and pressure during

exhaust

F11:30 134.2ºC 306.8k If cycle fails, conditions at time of failure.

CYCLE FAILED! ! ! Message displayed if cycle fails.

Manual Stop - 03 If operator presses the manual stop button.

♦ S11:28 099.9ºC 049.6k The time, temperature and pressure during

sterilization.

H10:08 134.3ºC 315.1k The time, temperature and pressure during the

heating stage.

H06:04 132.3ºC 304.1k The time, temperature and pressure during the

heating stage.

H02:00 116.2ºC 217.3k The time, temperature and pressure during the

heating stage.

H03:00 080.6ºC 023.1k The time, temperature and pressure during the

heating stage.

V00:27 078.3ºC 048.7k The time, temperature and pressure during air

removal (vacuum).

Exhaust mode: 1 Exhaust mode: fast exhaust and process ends

without pressure.

Dry time : 001 min Drying time of the selected program

Ster time: 001.0 min. Preset sterilization time of the selected program.

Ster Temp: 134ºC Sterilization temperature in chamber for selected

program.

Cycle: 01 Unwrapp Selected program: Unwrapped Instruments.

14/01/2003 13:29:31 Date/month/year time/mins./secs.

Version = HORIZ US3 eje Number and version of the software program.

♦ S above is not part of this cycle and has been added on for an explanation

of future reference to S - sterilization.

Legend

V - Vacuum stage

S - Sterilization stage

E - Exhaust stage

H - Heating stage

F - Fail

Page 76 of 117 pages

Page 82

10.2 Printer Handling

The printer is driven and controlled automatically by the control unit, while the autoclave performs a sterilization program.

To set the paper roll in the printer perform the following steps:

10.2.1 Gently push the clips for removing the front panel,

10.2.2 Set the paper roll on the shaft (See Figure 1). Since the

Figure 1 Figure 2

remove the panel and pull out the printer gently.

outer and inner surfaces of the paper are different set the roll so that the printing surface is the outer.

10.2.3 Gently push the paper face down into insertion opening (A) in Figure 2. Keep pressing the feed switch (B) until the paper comes out from the print head (C).

10.2.4 When the paper emerges from the print head, insert it in the paper cutter (the slot in the front panel) and reassemble the front panel on the unit.

The paper roll is set inside the unit and the printer is ready for use.

NOTE: If the paper is not pulled in by the rollers even when you press the feed switch (B) push the paper in.

10.2.5 To ensure a reliable operation of the printer perform the following:

10.2.5.1 Turn the main switch to the OFF position.

10.2.5.2 Turn the main switch to the ON position;

press the feed switch at the same time. Verify that the printer performs an operation test by printing all the built-in characters

The following precautions have to be taken ensuring the proper operation of the printer:

♦ Avoid contact between the paper and the hot parts of

the autoclave, as the paper will be blackened.

♦ Do not pull out the paper roll from the paper insertion

opening.

♦ Use only the 58mm. wide thermal paper rolls, supplied

by your dealer.

Page 77 of 117 pages

Page 83

11.MAINTENANCE OF AUTOCLAVE

11.1Preventive and Periodical Maintenance

Before each cycle

Daily User

Weekly User

Monthly Tech

3 months Tech

6 months Tech

Yearly Tech

User

Notes:

1. Keeping the inside of the autoclave clean will lengthen its life and its proper operation.

2. Use only mineral-free water as detailed in par. 2.5 ' Water quality'.

3. If you see or hear anything extraordinary, stop using the autoclave and call for service.

Periodical Tests

1. Once a year, calibrate and validate the autoclave.

2. Periodical safety tests referring to local rules, regulations or law shall be applied in compliance with the law.

1. Clean the strainer at the bottom of the chamber.

2. Verify that the door gasket and the surface that the gasket is pressed on are clean.

1. Before starting operation, ensure the compressor tank is drained of water (if applicable).

2. In case the autoclave is used to sterilize liquids, it is imperative to clean the chamber at the end of every day. Clean the chamber while the autoclave is

cold.

1. Clean the cabinet and door parts, the internal walls of the autoclave, the shelves and the shelf rails with a soft cloth and detergent. Clean the chamber

while the autoclave is cold. The detergent shall be flashed away. Caution

Do not use steel wool or steel brush as this can damage the chamber!

2. Place several drops of oil on all the door spindles and pins.

3. Drain the generator as follows: a. Switch off the power. b. Wait until the pressure decreases to 0.5 bar (watch the pressure gauge). c. Open the drainage manual valve for a few seconds till the glass tube

becomes empty, then close the valve.

d. Drain the water level tube by opening the tube’s valve located at the

bottom elbow connecting the tube to the vessel.

4. Verify that the water quality complies with the requirements as detailed in par.

2.5 ' Water quality'.

1. Allow the safety valve to blow off by letting the pressure increase until it reaches the working pressure + 10%. This verifies that the safety valve operates as required and the valve’s seat is kept free of mineral deposits.

1. Clean water strainers on pipelines while autoclave does not operate (idle).

2. Verify sewage pipe is not clogged ensuring free drainage of sewage liquids. It is important that sewage liquids do not overflow at the working site.

3. Disassemble the steam –traps and clean them. The cleaning operation requires cleaning of the filter inside the steam-trap. This can be done by rinsing and removing any dirt, which causes blockage.

4. Check the piping connections and tighten where necessary to avoid leakage.

5. Descale the generator (if applicable).

1. Replace the 0.01µ air filter

1. Perform an overall check of the locking system and replace worn parts.

2. Check and tighten where necessary the electrical connections in the electrical board, connection box, motors, electrical valves, locking device screws and instrumentation.

3. Clean the electronic control unit, using a vacuum cleaner.

4. Check the door gasket and Replace if damaged.

5. Ensure periodical tests are done on time.

6. Check the steam-traps and replace if worn.

Page 78 of 117 pages

Page 84

SERVICE INSTRUCTIONS

Page 79 of 117 pages

Page 85

11.2 Safety Tests after Repair

ATTENTION!

After every repair or dismantling the enclosure, the autoclave should pass two safety electrical test by the Service Engineer. The following shall be performed:

1. Enclosure Leakage Current Test.

Every autoclave should pass this test. The electrical potential of the testing instrument should be 500V and the test should be performed using the Megger The insulation resistance should be at least 2 MΩ. The test is successful if there was no leakage.

2. Protective Earth Impedance Test In the test should be measured the resistance between grounding screw on the rear plate (or any other metallic part) and the grounding pin of the power cord plug using the Ohmeter. The resistance should not exceed 0.3 Ω.

After performing these tests, the Service Engineer should complete and sign the Work Order.

Page 80 of 117 pages

Page 86

11.3 Troubleshooting

Symptoms

1. Control unit not energised. No displays and lights on the front panel.

2. STS generator does not operate.

Steam pressure goes beyond the control point.

3. Steam pressure goes beyond the control point.

Possible causes check-ups and

tests

1.1 The control circuit breaker switched off.

2.1 Water pump defective or blocked.

2.2 Blocking or low water pressure in the pump circuit.

2.3 Upper electrode short-circuited.

2.4 Pressure switch faulty or out of calibration.

2.5 Lower electrode dirty or rusted.

2.6 Contactor controlling the heat up current is damaged.

2.7 Control system trouble. 2.7 Replace boards.

2.8 Solenoid or pneumatic steam supply valve stuck or defective.

2.9 Vacuum in the water pump to STS generator.

2.10 Pressure switch faulty or incorrectly set.

3.1 Pressure transducer faulty or incorrectly set.

3.2 Contacts at contactor welded because of short circuit.

1.1 Check and switch on the circuit breaker.

2.1 Repair or replace pump. Replace motor.

2.2 Adjust water pressure, ensure a free circulation of water.

2.3 Clean or replace upper electrode.

2.4 Check, calibrate pressure switch or replace it.

2.5 Clean or replace the electrode.

2.6 Check the cause and replace contactor.

2.8 Repair or replace solenoid or pneumatic valve.

2.9 Release the manual tap next to the water reservoir to release vacuum in the water pump to prevent air pockets.

2.10 Check, repair or replace the pressure switch.

3.1 Check, repair or replace the pressure transducer.

3.2 Check the cause, replace the damaged contactor.

Corrections

Page 81 of 117 pages

Page 87

Symptoms

4.The conditioning phase (prevacuum does not work).

No steam inlet or low steam pressure.

5. Prevacuum phase completed but temperature and pressure are low and the sterilization point is not reached or takes a long time to reach it.

Possible causes check-ups and

tests

4.1 Check if the trouble is due to pump or its electrical supply circuit.

4.2 The vacuum valve passing water through the vacuum pump stuck or damaged.

4.3 The exhaust to pump valve stuck or damaged.

4.4 Door improperly closed, gasket damaged or incorrectly seated on the groove.

4.5 Leakage at the vacuum or exhaust piping.

4.6 Steam inlet valve blocked or damaged.

4.7 Low pressure at the steam supply line.

4.8 Control system trouble. 4.8 Replace the control

5.1

5.2

5.3 Electronic pressure

5.4 Control system trouble. 5.4 Replace the control

Low pressure at the steam supply line. Steam inlet valve clogged or damaged.

transducers or measuring circuits faulty or set too low.

4.1 See solutions indicated in par. 2.

4.2 Check, repair or replace the water to pump valve.

4.3 Check repair or replace the fast exhaust valve.

4.4 Close the door, fix or replace the gasket.

4.5 Check and tighten fitting joints, replace defective packing.

4.6 Fix or replace the steam valve.

4.7 Check the steam generator as shown in par. 2.

boards.

5.1

5.2

5.3 Set correctly or replace

Check steam generator, fix pressure. Check and fix or replace the steam valve.

boards.

Corrections

Page 82 of 117 pages

Page 88

Symptoms

6. Temperature rises above the preset sterilization value.

7. Fast or slow exhaust phases do not function; chamber pressure remains high or exhaust takes too long.

8. Drying stage does not work.

9. The air inlet does not work.

10. Unsatisfactory results of sterilization process.

Possible causes

check-ups and tests

6.1 Steam pressure too high. 6.1 Check and set

6.2 Steam valve leaks. 6.2 Fix or replace the

6.3 Control system trouble. 6.3 Replace control

7.1 The fast or slow exhaust valves stuck or damaged.

7.2 Steam valve leaks. 7.2 Repair or replace

7.3 Control system trouble. 7.3 Replace control

8.1 Trouble with the vacuum system.

8.2 Steam valve leaks. 8.2 Repair or replace

8.3 Control system trouble. 8.3 Replace control

9.1 Air inlet valve clogged or damaged.

9.2 Air filter clogged. 9.2 Replace air filter.

10.1 Incomplete removal of air pockets.

10.2 Sterilization conditions improper temperature or pressure too low, ste. time too short.

10.3 Incorrect loading of autoclave, air trapped in the load.

7.1 Repair or replace

8.1 See par. 2 and 4.

9.1 Repair or replace air

10.1 See trouble related to

10.2 Set correctly the temp.

10.3 See par. on

Corrections

correctly the pressure switch of the generator and the pressure reducer.

steam valve.

boards.

damaged valve.

steam valve.

boards.

steam valve.

boards.

valve.

vacuum system par. 2 and 4.

and time according to the sort and quantity of material.

‘Preparation before Sterilization’.

Page 83 of 117 pages

Page 89

Symptoms

11. Drying incomplete packs remain wet.

12. Problems related to the control system.

Possible causes

check-ups and tests

11.1 Insufficient steam pressure to jacket.

11.2 Insufficient vacuum. 11.2 See problems related

11.3 Steam trap does not eliminate the condensate.

11.4 Incorrect loading of the autoclave.

12.1 Check if the flat cable or MOLEX connectors between the control boards and keyboard are well plugged in.

12.2 Power supplies out of order. 12.2 Fix or replace the

12.3 Control boards or keyboard. 12.3 Replace defective

12.4 Paper to printer missing or quality unsuitable.

12.5 Flat cable connection between control board and printer is not plugged in correctly.

12.6 Printer damaged. 12.6 Replace the printer.

11.1 Set or fix the

11.3 Clean or repair the

11.4 Reload the autoclave

12.1 Plug in firmly the

12.4 Insert a paper roll

12.5 Plug in connection or

Corrections

pressure transducer.

to vacuum par. 2 and

steam trap.

appropriately.

MOLEX connectors.

power supply.

board of microcomputer unit.

inside the printer. Ensure the appropriate type of paper is used.

replace it.

12.7 Temperature sensor disconnected or loose connection. Sensor damaged.

12.8 Pressure transducer, bad. Mechanical or electrical connections or transducer damaged.

Page 84 of 117 pages

12.7 Fix connection or replace sensor.

12.8 Fix connection or replace transducer.

Page 90

Symptoms

13. Door not closing. 13.1 Low pressure at the air

13.2 Solenoid valve transmitting

13.3 Close Door button is

13.4 Safety switch stuck or

13.5 Control system trouble. 13.5 Replace the control

14. Door locked but chamber is not sealed.

15. Door not opening. 15.1 Low pressure at the air

14.1 Low pressure at the air

14.2 Low steam pressure at the

14.3 One of the two valves

14.4 Solenoid valves pressure or

14.5 Control system trouble. 14.5 Replace the control

15.2 Insufficient vacuum to

15.3 Gasket improperly seated or

15.4 Solenoid valves operating

15.5 The vacuum to gasket valve

15.6 The solenoid valve which

15.7 Control system trouble. 15.7 Replace control

Possible causes check-ups and

tests

supply line.

air pressure to door cylinder for lifting the door is stuck or damaged.

defective.

damaged.

supply.

door gasket.

pressure or vacuum to gasket blocked or damaged.

vacuum to gasket, blocked or damaged.

supply line.

gasket, due to trouble with the vacuum system.

damaged.

the two pneumatic valves, pressure to gasket or vacuum to gasket defective.

blocked or damaged.

transmits air pressure to the door cylinder for lowering the door is stuck or damaged.

Corrections

13.1 Set the air pressure.

13.2 Repair or replace the solenoid.

13.3 Replace the button.

13.4 Fix or replace the safety switch.

board.

14.1 Set the air pressure.

14.2 Set the steam pressure.

14.3 Fix or replace the pneumatic valve.

14.4 Repair or replace the solenoid valve.

boards.

15.1 Set the correct air pressure.

15.2 See par. 2.

15.3 Mount the gasket correctly, or replace it.

15.4 Repair or replace the damaged solenoid valve.

15.5 Replace or repair the damaged valve.

15.6 Replace or repair the valve.

boards.

Page 85 of 117 pages

Page 91

11.4 Troubleshooting for the Water Pump ‘SHURFLO’

Symptom Possible cause Corrections

1. Pump does not start.

1.1 Fuse burnt or circuit breaker tripped.

1.2 Wrong voltage.

1.3 Damaged electrical connection.

1.4 Faulty pressure switch.

1.5 Open or grounded circuit due to faulty rectifier or motor.

1.6 Locked drive assembly.

2. Pump does not prime (motor runs but water is not discharged.

2.1 No water supply.

2.2 Inlet water strainer clogged.

2.3 Vacuum leak in inlet line.

2.4 Inlet or outlet tube severely kinked.

2.5 Debris in pump inlet or outlet valves.

2.6 Pump operating on wrong voltage.

2.7 Pump housing damaged (cracks).

3. Leak from pump head or switch.

3.1 Loose screws at switch or pump head.

3.2 Switch diaphragm ruptured or pinched

4. Pump will not shut-off

4.1 Output line closed and no leaks.

4.2 Air trapped in outlet line or pump head.

4.3 Pump operating on wrong voltage.

4.4 Inlet or outlet valves clogged.

4.5 Loose drive assembly or pump head screw.

4.6 pressure switch operation/adjustment incorrect

1.1 Replace fuse or turn on the circuit breaker.

1.2 Use right voltage.

1.3 Fix connections.

1.4 Replace pump.

1.5 Replace pump.

1.6 Replace pump.

2.1 Fix water supply.

2.2 Clean inlet strainer.

2.3 Replace piping.

2.4 Straighten or replace tube.

2.5 Clean valves.

2.6 Use right voltage.

2.7 Replace pump.

3.1 Fasten screws

3.2 Replace damaged pump.

4.1 Open outlet line.

4.2 Remove trapped air.

4.3 Use right voltage.

4.4 Clean clogged valves.

4.5 Fasten loose screws.

4.6 Refer to S/B #1031 for differential and pressure adjustment procedure.

5. Pump runs loudly 5.1 Loose pump head or drive screws.

Page 86 of 117 pages

5.1 Tighten loose screws.

Page 92

11.5 Pressure Switch

Pressure Switch type RT 200:

This pressure switch regulates the steam pressure output of the generator. It is factory regulated, but in case this regulation is not accurate the following steps should be taken:

1. Turn pressure switch knob clockwise to decrease pressure.

2. Turn pressure switch knob counter clockwise to increase pressure.

Page 87 of 117 pages

Page 93

11.6 Absolute Pressure Transducer

The control unit is fitted with three pressure transducers, one for the control and monitoring of chamber pressure, the second for the control of jacket pressure and the third for gasket pressure.

The transducer type IMT 3296 is a membrane pressure sensor and electronic measuring circuit, having the following specifications: Pressure gauge: 0-4bar abs. Output span current: 4-20mA Supply voltage: 10V to 30V The pressure of the steam to the gasket should be 3 bars (45 psi), but the transducer is set at 1.5 bars (22 psi).

The terminals at the connector of the device are 1 (+24V) and 2 (OUT) to the controller output.

ELECTRIC CONNECTION

Page 88 of 117 pages

Page 94

11.7 Cleaning and Replacing the Water Level Electrodes

The two electrodes of the water level control system are located on top of the STS generator.

Cleaning

1. Turn off the electric power and release the steam pressure from the autoclave and the steam generator.

2. Disconnect the wire from the electrodes connections.

3. Open the nuts that tighten the electrodes.

4. Insert a new electrode and tighten the fixing bolt

to avoid leakage.

5. Reconnect the wires to the electrodes

Replacing

1. Remove the two electrodes. Keep in mind the place of the short and long electrodes.

2. Clean the electrodes.

3. Reassemble the two electrodes into their places.

4. Tighten the nuts to avoid leakage.

5. Reconnect the wire to the electrodes.

6. Test the unit.

Page 89 of 117 pages

Page 95

11.8 The GEN-PROTEC electronic board

The water level control system consists of two electrodes connected to an electronic board, which commands the operation of the water pump and servo solenoid valve and switches off the heating current in case of lack of water or low water level.

The electronic board G-PROTEC -V1 receives electric signals from two electrodes of different lengths, introduced in the pressure vessel through two openings located on top of the vessel.

The short electrode determines the water level in the boiler and the long electrode determines the minimum level, necessary to ensure a safe operation of the heaters.

The steam output pressure is regulated by the pressure switch, connected to the G-PROTEC-V1 electronic board, which switches the heating currents of the generator.

Refer below to layout and connection diagram of the electronic board G-PROTEC-V1(only the input and output connections relevant for this system, are configured in the drawing).

H.C

SSR1

SSR

AC IN

AC OUT

SSR1

SSR

AC IN

AC OUT

CB1

3-30 VDC

24V

WATER PUMP

JP2

1 2 3

HEATER

JP4

1 2 3

PUMP

GND

JP5

SUPPLY

LED1

LED8

LED2

GEN.PRO

LED3

LED4

LED5

LED6

LED7

JP1

INPUT

6 5 4 3 2 1

SW1

WATER PUMP FLOAT

PRESSTAT

L.ELECTROD

HEATER

H.ELECTROD

PUMP

Titl e

GEN.PRO BOAR D

Page 90 of 117 pages

Page 96

11.9 Water Pump Rear Endbell Replacement Kit

WARNING:

To prevent electrical shock, disconnect power before initiating any work. In the case of pump failure, the motor housing and/or the pumped fluid may carry high voltage to components normally considered safe.

CAUTION:

If the fluid being pumped is harmful, caustic, or hazardous take all necessary precautions to prevent equipment damage or personal injury. When the procedure outlined below is performed, the fluid side of the pump-head is not opened; however, relieving pressure within the outlet side of the pump is highly recommended.

Inspect the motor armature/commutator for any indication of the following conditions. Check the commutator brush contact surface for deep wear, scores, filled/shorted slots, or a burnt condition. Minimum commutator diameter is .850 in. [21.5 mm] (115 & 23OVAC). Check armature windings for open, shorts, internal ground, and commutator connections. The windings should not be overheated, black in color, or have a burnt odor. If the motor has any indication of the aforementioned or other failure modes, the endbell kit will not correct the failed condition. Complete motor assemblies. Contact Tuttnauer for a complete motor assembly.

11.9.1 Replacement Instructions

1. Mark the motor housing to index the location of endbell wires to the housing.

NOTE: If the endbell is improperly indexed to the motor housing (180°) the motor will rotate in the opposite direction.

2. Remove the two motor assembly screws using a 5/16” socket wrench or nut driver.

3. Remove the rear endbell assembly. Inspect for signs of excessive wear on the commutator and/or armature. Ensure the proper placement of washers on the shaft as shown.

4. Slide the new endbell assembly onto the shaft as far as the brush retention clip will permit.

Page 91 of 117 pages

Page 97

5. Index the endbell wires to mark made in step #1. Align endbell to the slots in the motor housing. Pull the brush retaining clip out while pressing the endbell flush to the motor housing.

6. Connect the black 115V (brown 230V) wire to the pump switch if applicable.

7. Install the motor assembly screws along with the green/yellow wire (115V only). Torque to 12÷18 m. lbs.

8. Perform Hi-Pot Test as follows:

1. The system conductors must be shorted together, and all switches must be turned “on”.

2. Hi-pot voltage is applied between the shorted conductors and accessible dead metal. The voltage frequency should be within the range of 40-70 hertz.

3. Voltage should be applied in accordance with either condition “A” or condition “B” per the table below.

CONDITION A CONDITION B

Appliance Rating

Less than 100

100 – 130 volts 1000 60 1200 1

210 – 240 volts 1480 60 1780 1

Potential

Volts



Time

Seconds

Potential

Volts

600 1

Time

Seconds

Page 92 of 117 pages

Page 98

11.10 Door Piston Oil Tank

11.10.1 Checking Oil Level

To check if the oil content in the tank is as required perform the following: Open the door to the lower position. Verify that when the door is open, the oil content in the oil tank is 80% of full capacity.

If the oil content in the tanks is below or over the required quantity add or remove oil according to the following instructions:

11.10.2 Adjusting Oil Quantity

1. When the door is in “open” position disconnect the compressed air supply to the autoclave (1).

2. Add oil through the oil filling plug (2) or remove oil from the tank using the drain manual valve (3).

3. Close well the drain valve and filling plug (as appropriate).

4. Reconnect the compressed air supply.

5. Close and open the door 5 – 10 times in order to drain air from the system.

Attention: Do not stand close to the door while reconnecting the compressed air supply to the autoclave.

Page 93 of 117 pages

Page 99

11.11 Dismantling the Cabinets Side Panels

Push the side cover upward and pull out (A).

Page 94 of 117 pages

Page 100

12. SPARE PARTS

Part No. Description R ARM 029 – 0001 R ARM 029 – 0006 R ARM 100 – 0012 R ARM 100 – 0069 R ARM 100 – 0070 R ARM 172 – 0004 R ARM 172 – 0005 R ARM 172 – 0012 R ARM 172 – 0018

- CTP 201 – 0002

- CTP 201 – 0003

- CTP 201 – 0044

R CTP 201 – 0065

- CTP 201 – 0079

- CTP 201 – 0090

- CTP 201 – 0091 R ELE 034 – 0018 R ELE 035 – 0012 R ELE 036 – 0003

- FIL 175 – 0014

- FIL 175 – 0023

- FIL 175 – 0035

R FIL 175 – 0039

- FIT 100 – 0313

- FIT 102 – 0296 R GAS 081 – 0004 R GAS 082 – 0005

GAS 084 – 0018 R GAU 029 – 0001 R GAU 029 – 0003 R GAU 029 – 0012

- GAU 029 – 0018

- GAU 029 – 0028 R GEN 350 – 0011 R GEN 350 – 0012 R GLA 028 – 0002 R PNE 100 – 0006

Pressure Reducer 1/2" ADCA Pressure Reducer 1/2" Stainless Steel Steam Trap, inverted bucket 1/2", ESCO Steam Trap 1/2" (elbow) without bypass Nicholson N125W Steam Trap 1/2" (elbow) with bypass Nicholson N125W SLR Non return valve 'SWING' 3/4" Non - return valve 'SWING' 1" Non return valve ‘Mondeo’ 1/2'’ Non return valve 'SWING' 1/2" Stainless Steel Power Supply PU65 - 14C Power Supply PU30 - 10LS GEN-PROTEC Board Solid State Relay (SSR) Control panel CAT 2004 HorizV5 board Horan R5 board Circuit Breaker 6A Main rocker switch M.Sw. Crouzet Strainer 1” Strainer 1/2” Stainless Steel Strainer 3/4” Stainless Steel Air Filter Domnick-Hunter 0.01 µ, 1/2” Fitting for water level tube Electrode holder Door Gasket 21 mm.- 26"x26" Glass Tube Gasket Reinforced flexible tube 1/2” Pressure Gauge - 1+60 Psi Pressure Gauge 0-60 Psi Air pressure gauge 1/4‘’ Main air pressure reducer MAFR 200 8A Secondary air pressure reducer MAR 200 8A Water Level Electrode (long) Water Level Electrode (short) Water level glass tube Short Teflon sleeve

- PNE 100 – 0007

- PNE 195 – 0022

- PNE 195 – 0024

Electrode nut Non return valve 1/8‘’ Locking valve

Page 95 of 117 pages