Tuttnauer E-Series Repair manual (2008)

Technicians Service and

Repair Manual

for

Tuttnauer Automatic

Autoclaves

Models E, EK, EA, EKA, EZ and EZ10K

Cat. No. MAN205-0310001EN Rev. C

 Tuttnauer USA Co., Ltd., 25 Power Drive, Hauppauge, NY 11788, USA, : (800) 624 5836, (631) 737 4850, Tech Service ext. 772, Fax: (631) 737 0720, Tech Service fax (631) 737 4855

e-mail: info@tuttnauerUSA.com

This manual is intended for the qualified technician. The instructions and guidance go into great detail, but basic trouble shooting and diagnostic skills are still required.

I want to thank all the members of the technical staff at Tuttnauer USA with out whose help this manual could not have been completed

Written by Henry Dierschke

Illustrated by Edward A. Hendrickson

Second Edition Januar 10, 2008

Revised Edition November 18, 2004

First Edition June 1, 2000

TABLE OF CONTENTS

PARAGRAPH PAGE NO.

1 General Information..................................................................... 5

1.1 The Tuttnauer Company................................................................. 5

1.2 Warranty .......................................................................................... 6

1.3 Theory of Operation ........................................................................ 7

2 Installation and Setup .................................................................. 9

2.1 Unpacking and Inspection............................................................... 9

2.2 Unit Location.................................................................................... 9

2.3 Voltage Requirements ................................................................... 10

2.4 Setup................................................................................................ 10

3 Front Panel Keypad.................................................................... 14

3.1 Front Panel Keypad....................................................................... 14

4 Display Messages ........................................................................19

4.1 Display Messages............................................................................ 19

5 Operating Instructions ...............................................................23

5.1 Preparation Before Sterilizing...................................................... 23

5.2 Filling The Reservoir ..................................................................... 25

5.3 Sterilization Programs................................................................... 26

5.4 Operating Instructions .................................................................. 29

5.5 Standard Sterilization Temperatures & Times........................... 31

6 Maintenance................................................................................32

6.1 Cleaning the Autoclave.................................................................. 32

6.2 Door Assembly Maintenance ........................................................ 37

6.3 Closing Device Maintenance ......................................................... 38

6.4 Solenoid Valves............................................................................... 39

6.5 Air Jet Maintenance ...................................................................... 41

6.6 Water Sensing Electrode............................................................... 42

6.7 Chamber Maintenance .................................................................. 43

6.8 Dry Pump Filter Maintenance...................................................... 43

6.9 Safety Relief Valve Maintenance.................................................. 43

6.10 Printed Circuit Board Maintenance............................................. 45

6.11 Filter Maintenance......................................................................... 46

7 Troubleshooting..........................................................................49

7.1 Power on Problem.......................................................................... 49

7.2 Heat up Problem ............................................................................ 52

7.3 Pressure Problem........................................................................... 55

7.4 Temperature Problem ................................................................... 58

7.5 Keypad Problem............................................................................. 61

7.6 Overheating Problem..................................................................... 62

7.7 Temperature Safety Thermostat Problems................................. 64

7.8 Circuit Breaker or Fuse Problem................................................. 65

7.9 Dry Pump Problem........................................................................ 69

7.10 Drying Problem.............................................................................. 72

7.11 Sterilizing Problem ........................................................................ 75

7.12 Fan Problem ................................................................................... 77

7.13 Odor Problem................................................................................. 79

7.14 Door Problem ................................................................................. 81

7.15 Water Fill Problem ........................................................................ 89

7.16 Leaking Water or Steam ............................................................... 95

7.17 Air Outlet Valve Problem ............................................................. 97

7.18 Display Problem............................................................................. 99

7.19 Power Supply Problem ................................................................ 101

7.20 Control Problem........................................................................... 105

7.21 Printer Problem ........................................................................... 107

7.22 Add Water Indicator Problem.................................................... 109

7.23 Door Closed Indicator Problem.................................................. 111

7.24 Memory Problem ......................................................................... 113

7.25 Exhaust Problem.......................................................................... 114

7.26 Cut-Out Thermostat Problems................................................... 116

7.27 Water Pump Problem.................................................................. 118

8 Testing and Calibration ........................................................... 121

8.1 SSR (Solid State Relay) ............................................................... 121

8.2 Testing Heating Elements............................................................ 124

8.3 Solenoid Valves............................................................................. 125

8.4 Temperature Sensor Calibration................................................ 127

8.5 Pressure Sensor Calibration ....................................................... 130

8.6 Automatic Water Fill Procedure ................................................ 133

8.7 Water Sensing Electrode Testing ............................................... 136

8.8 Temperature Safety Thermostat Testing................................... 138

8.9 Cut-Out Thermostat Testing ...................................................... 141

8.10 Dip Switch Selection .................................................................... 142

8.11 Available Test Equipment........................................................... 144

8.12 Finding the Software Version Number...................................... 148

8.13 In-Out Test ................................................................................... 149

9 Tables and Diagrams................................................................ 150

9.1 OHM and AMP Readings ........................................................... 150

9.2 Digital Predg Board ..................................................................... 151

9.3 Ajunc 2 Board Basic Layout ....................................................... 152

9.4 Ajunc 3 Board Basic Layout ....................................................... 153

9.5 Test Points for Ajunc 2 Board .................................................... 154

9.6 Test Points for Ajunc 3 Board .................................................... 155

9.7 Maximum Instrument Load ....................................................... 157

9.8 Maximum Textile Load ............................................................... 158

9.9 Maximum Liquid Load ............................................................... 159

9.10 Schematics .................................................................................... 160

9.11 Power Supply................................................................................ 163

9.12 LM34 Cross Reference Table ..................................................... 164

9.13 Solenoid Valve Schematic............................................................ 165

9.14 Autoclave Rear View ................................................................... 166

9.15 Autoclave Electronic Box Components...................................... 167

9.16 Chamber Brite Cleaning Instructions........................................ 168

10 Replacement.............................................................................. 169

10.1 Heating Element Replacement.................................................... 169

10.2 Temperature Safety Thermostat Replacement ......................... 172

10.3 Temperature Sensor Replacement ............................................. 174

10.4 Pressure Sensor Replacement..................................................... 176

10.5 Power Supply Replacement ........................................................ 177

10.6 Closing Device .............................................................................. 180

10.7 Solenoid Valve Replacement....................................................... 182

10.8 SSR (Solid State Relay) Replacement ........................................ 184

10.9 Air Jet Replacement .................................................................... 185

10.10 Water Sensing Electrode Replacement...................................... 185

10.11 Door Bellows Replacement.......................................................... 186

10.12 Chamber Replacement ................................................................ 188

10.13 Printer ........................................................................................... 189

10.14 Dry Pump Replacement .............................................................. 190

10.15 Safety Relief Valve Replacement................................................ 191

10.16 Float Switch Replacement........................................................... 192

10.17 Power Transistor Replacement .................................................. 193

10.18 Ajunc Board Replacement .......................................................... 194

10.19 Digital Predg Board Replacement.............................................. 196

10.20 Door Assembly Replacement ...................................................... 197

10.21 Fan Replacement.......................................................................... 198

10.22 Water Pump Replacement .......................................................... 198

10.23 Fuse and Fuse Holder Replacement........................................... 199

10.24 Circuit Breaker Replacement ..................................................... 199

11 Component Function in the Autoclave ...................................200

11.1 Temperature Safety Thermostat ................................................ 200

11.2 Cut-Out Thermostat .................................................................... 202

11.3 Air Jet............................................................................................ 203

11.4 Water Sensing Electrode ............................................................. 204

11.5 Door Bellows................................................................................. 205

11.6 Air Outlet Valve ........................................................................... 206

11.7 Printer ........................................................................................... 207

11.8 Fuse & Circuit Breaker............................................................... 209

1 General Information

1.1 The Tuttnauer Company

The Tuttnauer Company founded in 1925 produces infection control equipment for

the Dental, Medical, Veterinary and Laboratory markets. In addition, Tuttnauer produces large walk-in units for industrial, commercial and hospital applications. Tuttnauer equipment is distributed worldwide and the Tuttnauer Company is considered a leader in the field of Infection Control Apparatus.

Our main product line consists of manually operated and automatic sterilizers. The

following list shows past as well as currently available models of Tuttnauer sterilizers.

Manually operated models:

M = Manual MK = Manual Kwiklave*

Chamber sizes: 7” x 12”; 9” x 18”; (diameter x depth) 10” x 19”; 15” x 30” and 15” x 27”

Automatic models:

E = Electronic EA & EZ = Fully Automatic with Air Assisted Drying EK = Electronic Kwiklave * EKA & EZ10k = Fully Automatic Kwiklave * with Air Assisted Drying

Chamber sizes: 7” x 12”; 9” x 18”; (Diameter x Depth) 10” x 19”; 15” x 30” 15” x 27”

Tuttnauer offers a wide variety of standard models of autoclaves, as well as custom

designed units.

Additional Tuttnauer products:

• Chamber Brite autoclave cleaner

• Clean & Simple ultrasonic enzymatic cleaning solution in tablet form

• Ultrasonic Cleaners - 1 & 3 gallon

• Water Distillers – 1gal, 3.5gal, 8gal and 12gal

* Kwiklave units have faster cycle times than a standard unit, while maintaining

standard sterilization exposure times.

1.2 Warranty

Tuttnauer’s warranty covers defects in materials and workmanship on every

the autoclave. For exact details, see a formal copy of the Warranty Policy or call Tuttnauer at 1 800 624 5836.

This warranty covers both parts and labor for new

Tuttnauer warrantee’s chambers (on select models) for a period of ten (10) years

against any defects in materials and workmanship. This chamber warranty went into effect January 1997, (for more details call 1 800 624 5836).

These warranties do not apply to any improper installation or application; nor shall

it extend to products, which have been altered outside the factory without prior authorization from Tuttnauer; nor to products, which have been improperly maintained.

No product will be received or accepted for repair without proper return

authorization from Tuttnauer. All transportation charges to and from Tuttnauer are the responsibility of the owner of the autoclave. During the first 30 days after purchasing a new autoclave, Tuttnauer will pay shipping costs on an individually evaluated basis and ONLY with pre-approval.

This warranty will be void if the unit is not purchased from an authorized

Tuttnauer dealer.

To activate the warranty, the registration card must be completed and returned to

Tuttnauer within fourteen (14) days of purchase or you may call Customer Service at 1 800 624 5836.

Tuttnauer’s

No other warranties or obligations are expressed or implied.

obligation is limited to repair or replacement of parts for the autoclave.

autoclaves only.

part in

1.3 Theory of Operation

Theory of Operation – Electronic Steam Sterilizer Models E, EK, EA, EKA,

The Tuttnauer Steam Sterilizer is designed as a gravity displacement system. This

Water inside the autoclave Chamber is heated to produce steam. The rising steam

EZ and EZ10k

means that no other methods are used to move steam and air in or out of the Chamber other than the natural forces of gravity.

forces any air inside the Chamber to the top of the Chamber where it is bleed off by the Air Jet. This event is due solely to the effect of gravity on the steam and air. As the pressure builds within the Chamber, the air is continuously expelled through the unit’s Air Jet. The Air Jet is located in the water reservoir and connected by a copper tube to the top rear of the Chamber. The process of removing the air and leaving only steam in the Chamber is essential to the operation of the Sterilizer. Assisting the Air Jet in this function is the Air Outlet Valve. This valve participates in removing the air until a temperature of 195° is reached then the valve closes and any remaining air is removed by the Air Jet.

Steam temperature has a direct and important correlation to steam pressure. At

every level of pressure, steam has a specific corresponding temperature; this is a universally accepted fact. There is one stipulation required to make this true, there must be 100% steam present. For this reason, it is important that the air be removed as completely as possible from the Chamber. Removing the air is what allows the temperature to rise properly inside the Chamber.

The importance of a clean working Air Jet cannot be understated. The Air Jet has

two important functions:

 First is to remove the air from inside the Chamber while the unit is heating

up. If air were allowed to remain in the Chamber its presence would produce pockets of low and high temperatures. These uneven temperatures within the Chamber would result in areas of no sterilization. Only by removing the air can more uniform temperatures be attained and as a result, even and complete sterilization.

 The Air Jet has a second function, which is to maintain circulation within the

Chamber. It does this by remaining open after all the air has been bled off and continuing to purge the steam. This constant purging of steam causes motion within the Chamber. This constantly moving, constantly circulating steam is important in maintaining uniform temperature. Uneven steam temperatures can be the result of the heating elements turning on and off during the sterile cycle. This can cause hot and cold pockets of steam within the Chamber. If an instrument is in one of these cold pockets, it will not be sterilized even though the rest of the load was and the spore test confirmed a sterile load. The end result of keeping the steam in motion, because of the Air Jet, is that no pockets of uneven temperature will form and the load will be

Why use steam in the first place?

completely sterilized.

There are several reasons for preferring a steam Sterilizer.

♦ The first is that steam is non-toxic. ♦ The second is that steam sterilization is fast. Steam has excellent heat transfer

properties. Steam allows for tremendous amounts of heat energy to be transferred to the instruments instantaneously. This flash of energy is what destroys the biological contamination.

♦ Third, steam is readily available and easy to make from any water source. ♦ Fourth, equipment designed for steam sterilization is simpler to manufacture

Basic operation of the autoclave.

and use.

1. The operator closes the door and presses start.

2. Water flows into the Chamber; the Air Outlet Valve is open so that the water can flow in smoothly. Water flowing into a hot sealed Chamber will build pressure immediately, exerting a force on the water that can slow or even stop it from entering the Chamber. The open Air Outlet Valve provides an escape for that pressure, releasing that pressure allows the water to flow easily.

3. The autoclave heats to the proper temperature, controlled by the temperature and pressure sensor. The Air Outlet Valve closes at 195°F. Air escapes the Chamber through the Air Jet.

4. Once the temperature is reached, the timer counts down the programmed amount of sterilization time. Steam continues to purge through the Air Jet eliminating any differences of temperature that can occur within the Chamber.

5. The autoclave exhausts and the sterilization is complete.

2 Installation and Setup

2.1 Unpacking and Inspection

Upon receiving the autoclave, carefully inspect the outside of the shipping carton

for any signs of damage. If any damage to the shipping carton is found, note the location with respect to the autoclave and check that area of the autoclave carefully once it is fully unpacked. In addition, once the autoclave is fully unpacked, carefully check for any signs of physical damage such as; scratched panels, broken knobs, broken door covers, etc…

If any damage is found, contact the dealer as soon as possible so that they can file a

claim with the shipping carrier and also notify Tuttnauer.

All Tuttnauer 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.

Note: Lifting and carrying should always be done by two people

2.2 Unit Location

The unit should be located on a stable, solid countertop. In the case of the 3850

and 3870 models a table is provided with the unit.

It is not recommended that units be stacked. Adequate clearance is required above

the autoclave for the purpose of filling the reservoir with distilled water. In addition, some steam escapes through the filling hole. If overhead cabinets are too close, steam damage can occur to the underside of the cabinets.

A minimum of one inch clearance is required on each side and at the back of the

autoclave for access and ventilation.

Note: Lifting and carrying should always be done by two people

2.3 Voltage Requirements

All 110 volt units need to have a stable voltage between 110 and 125 volts AC.

All 220 volt units need to have a stable voltage between 220 and 235 volts AC.

For EK, EKA and EZ10k units, check that the incoming voltage is between 220

volts and 235 volts AC. This is important because too high a voltage will damage the heating elements and too low a voltage will cause the sterilizer to run slower. In either case, a Buck/Boost Transformer is recommended to correct the voltage. A Buck/Boost Transformer is relatively inexpensive and can be configured to either raise or lower the voltage.

It is recommended that all autoclaves be installed on a direct line.

The use of a surge suppressor is recommended, especially in areas where there

is a large fluctuation in voltage or frequent lightning strikes.

2.4 Setup

There are two procedures for setup depending on if the autoclave has a Water

Pump or not.

2.4.1 Setup and Automatic Filling for Units Without

These units will have Microprocessors with Software version numbers that

In these units the Chamber is filled from the Reservoir by gravity flow.

Adjusting the Chamber Pitch

Proper adjustment of the Chamber pitch and Automatic Fill are among the

contain the letters WP [see sec. 8.12].

do not

most important things you can do for the sterilizer. Proper Chamber pitch and Automatic Filling insures that the sterilizer will have the proper amount of water in the Chamber at the beginning of each cycle. Insufficient water in the Chamber, at the beginning of the cycle, will generate a LOW WATER message at some point during the cycle, when the water level becomes too low. If, on the other hand, there is too much water in the Chamber, this will extend the heating portion of the cycle. In cases where the heating portion of the cycle is extended for more than 50 minutes (or 80 minutes for a 3850 / 3870) the sterilizer will abort that cycle.

♦ Start with a sturdy, level counter. ♦ Make sure all the feet are on the autoclave and none have been lost. ♦ Make sure the front feet are free to move in and out. ♦ Position the autoclave on the counter. ♦ Fill the Reservoir with distilled water [see sec. 5.2].

Water Pumps

♦ The Chamber should be empty of any instruments, trays or leftover

water.

♦ The autoclave should be turned off. ♦ The Chamber pitch now needs to be adjusted correctly. ♦ Measure out the proper amount of distilled water for the appropriate

model unit as listed below:

1730 = 10 oz. (300ml) 2340 = 14 oz. (400ml) 2540 = 14 oz. (400ml)

3140 (3545) = 17 oz. (500ml)

3850 = 24 oz. (700ml) 3870 = 29 oz. (850ml)

All water volumes can be +2 oz and – 0 oz

♦ Pour the proper amount of water into the Chamber through the front

door of the unit.

♦ The water should cover the bottom of the Chamber to within +/- ½ inch

of the grove in the front.

♦ If necessary, adjust the front Leveling Feet so that the water lies in the

Chamber correctly.

♦ Once the Chamber pitch adjustment is completed, empty the water from

the Chamber and check if the automatic filling is set correctly.

Checking the Automatic Fill

To check the automatic filling procedure, follow the next few steps:

♦ Remove any water that is in the Chamber. ♦ Make sure the unit is turned on. ♦ With the Door open, press and hold ♦ Press the START Key. ♦ When water starts flowing into the Chamber, release the Door Switch. ♦ Water should come up to the same spot as the measured amount had. ♦ If the water fill is not working correctly, try the adjustment procedure or

check for a system problem [see sec. 7.15].

Automatic Filling Adjustment Procedure

♦ Make sure the power is off. ♦ The Door should be open. ♦ Press and hold

Keypad with the two arrows).

♦ Turn the power on. ♦ When the normal display screen appears, release the Water Inlet Key –

wait one second and then press it in again.

♦ Water should begin flowing into the Chamber. ♦ Monitor the water flow into the Chamber. ♦ Hold the Water Inlet Key until water reaches the groove at the front. ♦ Release the button – wait ten seconds – the unit is now reprogrammed

and ready to use.

the Water Inlet Key (this is the button on the front

the Door Switch.

2.4.2 Setup and Automatic Filling for Units With Water Pumps

Any unit with a Microprocessor Software version number ending in WP

[see sec. 8.12] will have a Water Pump installed to insure proper filling.

water.

♦ The unit is now ready to use.

To calibrate the automatic fill follow this procedure:

1. Press the STOP Key repeatedly until the message “Code: xxx” appears.

2. Using the UP/DN arrow keys change the code to 105 and press the STOP Key.

3. A message will be displayed saying “Water in = xx sec.”

4. Using the UP/DN arrow keys, change the seconds according to the following table:

2340/EZ9 = 30 sec 2540/EZ10/EZ10K = 35 sec 3140 = 40 sec 3850 = 45 sec 3870 = 65 sec

5. Press the STOP Key.

6. On some units the message “Ea Type:” may appear, using the UP/DN arrow keys select either “0” for an E or EK type unit or “1” for an EA or EKA type unit.

7. Press the STOP Key to finish.

3 Front Panel Keypad

3.1 Front Panel Keypad

The Front Keypad is divided into four sections, top, upper middle, lower middle

and bottom. There are two keyboard types (see below):

New Type (blue) Old Type (gray)

The Top Section has four lighted buttons; these represent the four available

programs. Each program comes preset from the factory with default parameters. Each program can, however, be modified by the operator. If necessary, the default or modified parameters can be locked-in [see sec. 8.10]. When a program is selected, the light in that button will illuminate and the program parameters will appear in the display.

Moving from left to right the programs are:

Unwrapped Instruments – symbolized by a pair of scissors

The default parameters are:

273°F for temperature 3 minutes of sterilization time Rapid exhaust No drying time

Wrapped Instruments – symbolized by a gown

The default parameters are:

273°F for temperature 7 minutes of sterilization time Rapid exhaust 30 minutes of drying time

Liquids/Glassware – symbolized by a flask

The default parameters are: 250 °F for temperature 30 minutes of sterilization time Slow exhaust only No dry time, drying is not allowed

Extra Drying Cycle – symbolized by the fan The default parameter is: 30 minutes of drying time

The purpose of the Extra Drying Cycle is to offer an alternative in situations

where the dry time in the wrapped or unwrapped cycle is insufficient. Rather than wait for the items to air dry or run another complete cycle with a longer dry time, just select the Extra Drying Cycle to continue the heat assisted drying process.

The Upper Middle Section consists of a:

Display – The Display is comprised of a single row of 16 characters and this row is divided

into four sections.

♦ When the system is running a program, the screen will display the current

temperature and pressure within the Chamber and the remaining time for sterilization or drying.

♦ The first three sections from left to right are designed to show the parameters of

the selected program or any operating messages.

♦ When the system is idle, the display will show the parameters of the currently

selected program.

♦ When the system is running a program, the actual sterilization temperature is

displayed above the TEMP Key. The remaining sterilization time will be displayed above the STE TIME key and the remaining drying time will be displayed above the DRY TIME Key.

♦ If the program aborts as a result of a program check or manual stop, a message

will be displayed on the screen. When a message is displayed, pressing any key will erase the message and redisplay the selected program.

♦ The last section of the screen, on the right, will continually display the actual

current real pressure inside the Chamber and this occurs whether a program is running or not (provided the main power is on).

TEMP Key – The TEMP Key is used to change the temperature parameter of the Wrapped,

Unwrapped or Liquids/Glassware programs. This can only be done while the

autoclave is not running a cycle. Press the TEMP Key and a cursor will appear under the temperature parameter. Use the Up/Down Arrow Keys to change to the desired temperature. After a few seconds of inactivity the cursor will disappear and the parameter will be locked in. The acceptable range for proper sterilization of wrapped and unwrapped items is between 250°F and 274°F (121°C and 134°C). For liquids the maximum temperature is 250°F (121°C).

In addition, the TEMP Key can be used to change the temperature display from

Fahrenheit to Centigrade. This can be accomplished by simply turning the power off, pressing and holding the TEMP Key and turning the power back on.

STE TIME – The STE TIME Key is used to change the sterilization time parameter of the

Wrapped, Unwrapped or Liquids/Glassware programs. This can only be done

while the autoclave is not running a cycle. Press the STE TIME Key and a cursor

will appear under the sterilization time parameter. Use the Up/Down Arrow Keys to change to the desired sterilization time. After a few seconds of inactivity the cursor will disappear and the parameter will be locked in.

DRY TIME – The DRY TIME Key is used to change the dry time parameter of the Wrapped,

Unwrapped and Extra Drying programs. This can only be done while the

autoclave is not running a cycle. Press the DRY TIME Key and a cursor will appear under the dry time parameter. Use the Up/Down Arrow Keys to change to the desired dry time. After a few seconds of inactivity the cursor will disappear and the parameter will be locked in. The acceptable range for drying time is 0 to 99 minutes.

In addition, the DRY TIME Key can be used to change the pressure display from

psi to bar (on all machines up to and including Microprocessors dated T93N6) or from psi to kpa (on all machines with Microprocessors dated T96DN1 or T97DN6 or later). This can be accomplished by simply turning the power off, pressing and holding the DRY TIME Key and turning the power back on.

CLOCK Key –

Pressing the CLOCK Key once will display the current date with a cursor under

the day parameter. Pressing the Up/Down Arrow Keys will change the day parameter. Pressing the CLOCK Key once again will move the cursor underneath the month and the year parameters. Once the date has been updated, pressing the

CLOCK Key again will display the time with the cursor under the hour. Use the Up/Down Arrow Keys as before to change the hours, run through the minutes and

seconds pressing the CLOCK Key each time to make the advance. After a few seconds of inactivity the cursor will disappear and the parameters will be locked in.

UP / DOWN Arrow Keys

Pressing these keys will raise or lower the values on any of the parameters that are

user adjustable.

The Lower Middle Section consists of a:

STOP Key –

This is the only key recognized by the system while a cycle is running. Pressing

the STOP Key for over one second will cause the current program to abort and the MAN STOP message to be displayed.

In addition, the STOP Key can be used to reset all the parameters back to their

factory defaults. This includes the Automatic Fill, in which case it will be necessary to recalibrate the Automatic Fill.

♦ Turn the power off ♦ Press and hold the STOP Key ♦ Turn the power on

START Key –

Pressing this key will start whichever program cycle has been selected and cause

the START Key light to turn on.

Water Inlet Key–

This key is symbolized by the two horizontal arrows pointing in through a channel.

Pressing and holding this key allows for the manual filling of the Chamber with water. This is useful for calibrating the Automatic Fill, also during cleaning to flush out the Chamber and in case it becomes necessary to bypass the Automatic Fill before running a cycle. Water will flow into the Chamber only as long as the key is depressed.

The Bottom Section consists only of indicator lights. Looking from left to right

they are the:

HEAT Light – A steady illumination is given when the autoclave is heating up at the beginning of

the cycle.

Also, this light will flash during the preheat/standby mode on units in which that

option has been activated (all EK, EKA, EZ10K, 3850 and 3870 machines).

STE Light – A steady illumination is given while the autoclave is in the sterilization portion of

the cycle.

EXH Light – A steady illumination is given when the autoclave is exhausting the Chamber.

DRY Light – A steady illumination is given while the autoclave is in the Drying mode.

CYCLE FAIL Light – Will illuminate anytime the autoclave detects a problem that results in an aborted

cycle.

ADD WATER Light – This indicator will light when the Reservoir is low on water. If the indicator lights,

after the Start Key has been pressed, the system will continue with the cycle.

There is sufficient water in the reservoir to complete this cycle. The next cycle will

not be allowed to begin until sufficient water is in the reservoir.

DOOR CLOSED Light – This indicator lights to signal that the Door of the autoclave has been closed.

4 Display Messages

4.1 Display Messages

Anytime

These messages are in the form of words that describe the problem the unit has

encountered.

The following is a list of those Error Messages with descriptions of what they

mean and indications where the problem may be:

LOW WATER This message will be displayed, if during a normal Heat Up

stage, the system determines that there is insufficient water in

the Chamber to complete the cycle. This determination is

made by the combined input of two sensors, the Water

Electrode and the Temperature Safety Thermostat.

Also,

stage after

in order to resume the cycle. If not,

Fail indicator will light.

Possible causes for this message are:

LOW HEAT This message is displayed, the Cycle Fail indicator lights

and the cycle is aborted, if the autoclave has not reached

sterilization temperature after heating for 50 minutes in

either Wrapped or Unwrapped programs (80 minutes in the

Liquid program).

Low Heat refers to the temperature in the Chamber before

sterilization has begun.

a cycle is aborted, the Tuttnauer autoclave will give an error message.

if a power failure occurs during the Heat or Sterilization

the power returns, the system will check the Water

Electrode to see if there is sufficient water in the Chamber

the cycle will be aborted,

the message LOW WATER will be displayed, and the Cycle

a. Insufficient water entered the Chamber at the beginning of

the cycle.

Check for proper leveling, a dirty or shorted Water

Sensing Electrode, a clogged Water Pump, a partially clogged line or that the Air Outlet Valve is stuck closed.

b. A leaky Solenoid Valve, Safety Valve, Air Jet, Door

Gasket, Door Bellows or a pipe fitting is allowing water or steam to escape at a higher than normal rate.

c. A power down has occurred and on power up, if the water

Electrode tip is dry the Low Water message will be displayed.

Possible causes for this message are:

a. No power to the Heating Elements. b. Bad Heating Elements. c. Very low line voltage delaying heat up. d. Temperature Safety Thermostat is opening prematurely,

turning off the Heating Elements. This only applies to units with Microprocessors dated earlier than T93N5 or

T93N6. e. A clogged Air Jet. f. An Air Outlet Valve stuck closed.

LOW TEMP This message is displayed if the Cycle Fail indicator lights,

the cycle is aborted and the temperature drops 4.5

F (2.5oC)

below the required sterilization temperature.

Possible causes for this message are:

a. Insufficient water in the Chamber (see Low Water

message). b. The sterilization phase of the cycle has been set for too

long a period of time, allowing the Chamber water to boil

away and the Chamber to run dry. c. The Temperature Safety Thermostat is opening

prematurely, turning off the Heating Elements -- this only

applies to units with Microprocessors dated earlier than

T93N5 or T93N6. d. A bad Temperature Sensor.

LOW PRES This message is displayed, the Cycle Fail indicator lights, and

the cycle is aborted if the pressure drops 4 PSI (0.27 BAR) below the required sterilization pressure.

Possible causes for this message are:

a. Insufficient water in the Chamber (see Low Water

message). b. The

Heating Elements are not cycling on and off properly.

1. Problem is with the Solid State Relay.

2. Problem with the control circuit.

c. Bad

Heating Elements -- not producing enough wattage.

d. The Temperature Safety Thermostat is opening

prematurely, turning off

the Heating Elements -- this only

applies to units with Microprocessors dated earlier than

T93N5 or T93N6. e. A bad Pressure Transducer.

HIGH TEMP This message is displayed, the Cycle Fail indicator lights and

the cycle is aborted if the temperature rises 9oF (5oC) above

the required sterilization temperature during the Sterilization phase of the cycle.

This message will also be displayed if the Temperature

Sensor is damaged. In this case, the message will appear just before the Heat phase starts.

Possible causes for this message are:

a. The Heating Elements are remaining on instead of cycling

on and off. Check for a shorted Solid State Relay, shorted Heating

Element or other short circuit. b. This message can ALSO indicate a bad Temperature

Sensor -- the message will display anytime during the Heat

Up phase.

HIGH PRES This message is displayed, the Cycle Fail indicator lights, and

the cycle is aborted if the pressure rises 10 PSI (0.6 BAR) above the required sterilization pressure.

Possible causes for this message are:

a. The Heating Elements are remaining on instead of cycling

on and off. Check for a shorted Solid State Relay, shorted Heating

Element or other short circuit. b. The

Sterilization temperature has been set above 274°F.

MAN STOP This message will be displayed and the Cycle Fail indicator

will light after the STOP Key is depressed for longer than 1 second.

RENEW WATER This message is displayed only as information to the operator

that the Water Reservoir should be drained and refilled with clean distilled water. This message will only appear on units with Microprocessors having software version numbers earlier than and including T93N5.

POWER DN This message is displayed, once the power is restored, after a

power failure occurs during the running of a cycle. The POWER DN message will be displayed for several seconds, and if present, the Printer will print POWER DN on the print out.

Once power has been restored the autoclave will make an

attempt to resume the current cycle from the point at which it was interrupted.

♦ If a power failure occurs during the Heat Up phase,

heating will resume (provided there is enough water in the

Chamber. If not, the cycle will be aborted). ♦ Exhaust and Dry phases will automatically resume

operation once power is restored. ♦ If the power down occurred during the Sterilization

portion of the cycle, when power is restored, the autoclave

will check if the temperature in the Chamber has fallen

more than 4.5°F (2.5°C). If not, the Sterilization Cycle will

resume automatically. If, however, when the power returns

and the system determined that the temperature has fallen

more than 4.5°F (2.5°C), the Sterilization Cycle will abort

and the Exhaust Cycle will start. ♦ If a power failure occurs during the Liquids program, the

system will not

allow a fast exhaust (as the exhaust valve is normally closed), nor will it fast exhaust when power comes back on.

ADD WATER This message is displayed and the ADD WATER indicator

lights to show insufficient water in the Water Reservoir. If this message is displayed after the START Key has been pressed is

, the system is not allowed to proceed. After water

added to the Reservoir, the START Key must be depressed

again in order for the selected cycle to begin.

DOOR UNLOCK This message will be displayed and the DOOR CLOSED

indicator will remain unlit if the door is improperly closed when

the START Key is depressed. Once the door is properly

closed, the DOOR CLOSED indicator will light and the START Key should be depressed to start the desired cycle. If the door becomes ajar during any stage of the cycle, the same message and indicator will appear, and the system will abort, the Cycle Fail indicator will light and the DOOR

UNLOCK message will be displayed.

WATER INLET This message will be displayed as information to the operator

while water is entering the Chamber, during the Automatic Water Filling process.

CYC FINISHED This message is displayed at the end of a successfully

completed cycle.

5 Operating Instructions

5.1 Preparation Before Sterilizing

Note: These instructions are provided as a minimum

Instruments to be sterilized must be free from all residual matter, such as blood or

organic tissue. Instruments must also be dry and free from mineral deposits. Such substances may cause damage to the instruments themselves or the Sterilizer.

1. Clean instruments immediately after use to remove any residue. It is recommended that all instruments be ultrasonically cleaned using Tuttnauer's CLEAN AND SIMPLE enzymatic cleaning tablets or other suitable solution.

2. After cleaning, rinse instruments for 30 seconds and pat or air dry.

3. Follow the instrument manufacturer’s instructions on the use of products for cleaning and lubricating instruments that have been ultrasonically cleaned.

4. Be sure that instruments of dissimilar metals (stainless steel, carbon steel, etc.) are separated. Carbon steel instruments should be bagged or placed on autoclavable towels and not directly on stainless steel trays.

5. When using a paper/plastic bag, the plastic side should always be down.

6. Check the instructions of the item manufacturer as to the proper procedure for sterilizing each item.

7. Items must be sterilized in an open position. Surfaces that are hidden because the item is in a closed position will not be exposed to the steam and will not be sterilized.

8. Place a sterilization indicator in each tray or inside each wrapped pack.

9. At least once a week use a biological spore test (Bacillus Stearothermophilus) in any load to insure proper sterilization, (be aware testing standards may vary). Always follow the spore test manufacturer’s instructions.

10. Make sure that all instruments remain apart during the sterilization cycle. Surfaces that are hidden because items are covering other items will not be exposed to the steam and will not be sterilized.

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

guideline.

12. Do not overload the Sterilizer trays. Overloading will cause inadequate sterilization and drying (see table 9.7 for loading limits for each model).

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

14. Wrapped instruments should be placed in material, which will allow steam penetration and promote drying, such as an autoclave bag, autoclave paper, or muslin towels.

15. Do not stack pouches. It is recommended that a pouch rack, such as the Tuttnauer Pouch Rack, be used to insure proper steam penetration and adequate drying. Surfaces that are hidden because the items are being stacked will not be exposed to the steam and will not be sterilized.

16. Tubing should be rinsed after cleaning. When placed in the tray, make sure that both ends of the tubing are open and there are no sharp bends or twists.

17. Packs should be placed upright on the tray. They should not be touching each other or the Chamber walls. There should be about 1” between packs for proper steam circulation.

18. Liquids should only be sterilized in heatproof glass. The beaker should only be filled 2/3 full and the lid should be on loosely to allow for expansion (see the table 9.9 for the maximum liquid capacity for each model).

19. If spotting were detected on the instruments, the first step would be to use an ordinary eraser to remove the spot. If there is no pitting under the spot, the spot was only dirt. Dirt spots on an instrument may be an indication that the autoclave needs to be cleaned or that the instruments were not adequately cleaned or dried. If removal of the spot reveals pitting, the spot was most likely rust. Rust spots on an instrument are not uncommon on inexpensive instruments. It may also be an indication that the instruments were rinsed in tap water with a high content of minerals. These minerals when exposed to high temperature and steam will accelerate the oxidation of the metal. One suggestion would be to final rinse the instruments in distilled water.

20. If the instruments exhibit a discoloration, this can be due to the mixing of carbon steel and stainless steel. When these two metals come into contact with each other, electrolysis occurs that breaks down the metal. The best solution is to separately wrap the carbon steel to insulate it from other instruments or the trays.

21. Items should not be allowed to touch the walls of the Chamber as the hot metal can damage the item.

5.2 Filling The Reservoir

Always use DISTILLED WATER in the autoclave for sterilizing. Using water of

a poorer quality will cause increased maintenance due to the mineral residue that accumulates in the various parts of the autoclave.

The Reservoir is filled from the top of the autoclave. Remove the Reservoir Cover

and pour water through the opening. Continue filling until the water reaches the base of the Safety Valve Holder. Under no circumstances should the Reservoir be filled above the Safety Valve Holder. The Reservoir should never be filled while the autoclave is running a cycle. If the Reservoir is filled while the Autoclave is running, at the end of the cycle, water exhausted from the Chamber can cause the Reservoir to overflow.

Overfilling or the failure to use Distilled Water will lead to clogging of the hole in

the Air Jet. This will be evidenced by the lack of both a hissing sound and a stream of steam coming from the Air Jet during sterilization. When this situation occurs, follow the instructions in sec. 6.5 for cleaning the Air Jet.

5.3 Sterilization Programs

Program 1 – Unwrapped Instruments

This program is for sterilizing unwrapped instruments and materials, that the manufacturer of these items has recommended autoclaving, at a temperature between 250°F and 274°F (121°C and 134°C).

This program comes set with these default parameters: Sterilization temperature 273°F Sterilization time 3 minutes Dry time none

These values can be altered to fit the needs of a particular office.

The parameters can only be changed while the autoclave is not running a

cycle.

Press the TEMP Key and a cursor will appear under the temperature

parameter. Use the Up/Down Arrow Keys to change to the desired

temperature. The acceptable range for proper sterilization of unwrapped

items is between 250°F and 274°F (121°C and 134°C).

*** Caution – in no case should the temperature be set higher than

274

°F (134°C) ***

Any change of temperature must be coordinated with a corresponding

change in sterilization time.

Press the STE TIME Key and a cursor will appear under the sterilization

time parameter. Use the Up/Down Arrow Keys to change to the desired

sterilization time.

If drying is desired, press the DRY TIME Key and a cursor will appear

under the dry time parameter. Use the Up/Down Arrow Keys to change to

the desired dry time. The acceptable range for drying time is 0 to 99

minutes.

After a few seconds of inactivity the cursor will disappear and the

parameter will be locked in.

Program 2 – Wrapped Instruments

This program is for sterilizing wrapped instruments and materials, that the

manufacturer of these items has recommended autoclaving, at a

temperature between 250°F and 274°F (121°C and 134°C).

This program comes set with these default parameters:

Sterilization temperature 273°F

Sterilization time 7 minutes

Dry time 30 minutes

These values can be altered to fit the needs of a particular office.

The parameters can only be changed while the autoclave is not running a

cycle.

Press the TEMP Key and a cursor will appear under the temperature

parameter. Use the Up/Down Arrow Keys to change to the desired

temperature. The acceptable range for proper sterilization of unwrapped

items is between 250°F and 274°F (121°C and 134°C).

*** Caution – in no case should the temperature be set higher than

Any change of temperature must be coordinated with a corresponding

change in sterilization time.

Press the STE TIME Key and a cursor will appear under the sterilization

time parameter. Use the Up/Down Arrow Keys to change to the desired

sterilization time.

If a longer or shorter drying is desired, press the DRY TIME Key and a

cursor will appear under the dry time parameter. Use the Up/Down Arrow

Keys to change to the desired dry time. The acceptable range for drying

time is 0 to 99 minutes.

After a few seconds of inactivity, the cursor will disappear and the

parameter will be locked in.

274

°F (134°C) ***

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Tuttnauer E-Series Repair manual (2008)

Specifications and Main Features

Frequently Asked Questions

User Manual