Tuttnauer 6671130 Autoclave - User and Maintenance Manual
Tuttnauer 6671130 Autoclave - User and Maintenance Manual
Tuttnauer 6671130 Autoclave - User and Maintenance Manual
&
MAINTENANCE
MANUAL
Pre-Vacuum Steam Heated Autoclave
with one Vertical Sliding Door
and a 36 kW Steam Generator
Model 6671130 2VEP
S.N: 1102058
1. GENERAL INFORMATION
2. INSTALLATION
2.2 Mounting------------------------------------------------------------------------------------------- 11
3. FUNCTIONAL DESCRIPTION
5. PRINTER
6. STERILIZATION PROGRAMS
SERVICE INSTRUCTIONS
9.6 The SHURFLO Water Pump Rear Endbell Replacement Kit ----------------------- 93
9.11 Working with power ON in Service Area (Autoclaves with sliding doors) -------- 106
Set of Drawings
WARRANTY
We certify that this device 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 the Preventive and Periodical
Maintenance paragraph.
Our obligation is limited to replacing the device or parts, after our examination, if within
one year after the date of shipment if they prove to be defective. This warranty does not
apply to any device that 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 that we may be able to identify the problem and hence provide a prompt solution.
For technical information or service please contact:
PARAMEDICOS de EL SALVADOR
Prolongacion Calle Arce,
Edificio # 3020,
Entre 57 Y 59,
Av. Norte.
San Salvador,
EL SALVADOR.
Tel: 2265-2099
e-mail [email protected]
Warning!
Never use the autoclave for the sterilization of corrosive products and chemicals ,
such as: Acids, bases and phenols, volatile compounds or solutions such
ethanol, methanol or chloroform nor radioactive substances.
Safety Operation Instructions
1. NEVER start a new autoclave or a new steam generator, before the safety,
licensing, and authorization department has not approved it for use.
2. All autoclave users must receive training in proper usage from an experienced
employee. Every new employee must undergo a training period under an
experienced employee.
3. A written procedure must be established for autoclave operation, including:
Daily safety tests; seal inspection and door hinge inspection; smooth action of
the closing mechanism; chamber cleaning; prevention of clogging;
preservation from corrosion; and finally, what is permitted and what is
prohibited for sterilization and choosing a sterilization program.
4. If there is a steam generator – drain it daily.
5. If there is an air compressor – drain it daily.
6. Before use, check inside the autoclave chamber to ensure that no items have
been left from a previous cycle.
7. Before loading the autoclave, clean the strainer on the chamber floor.
8. Load trays in such a way as to allow steam to move freely among all items.
9. Liquids may be sterilized only with the ―liquids‖ program. The container must
be covered but not sealed. Sealed bottles may only be sterilized using a
special program. The bottle must be either Pyrex or a Borosilicate glass bottle.
10. When sterilizing plastic materials, make sure that the item can withstand
sterilization temperature. Plastic that melts in the chamber is liable to cause a
great deal of damage.
The autoclave operates with saturated steam as the sterilizing agent, and has a
temperature range of up to 137C (279ºF) and pressure up to 2.3 bar (34 psi).
The autoclave is equipped with a 36 kW built-in steam generator. This steam generator
acts as a standby if building steam is not available for the sterilization process.
The autoclave is built to receive two steam supply sources, namely from the building, or
from an internal built in steam generator. There is a selector switch on the Front Panel to
choose the source. Before selecting the external generator, check the generator is
connected to the electrical supply and working properly.
The autoclave is equipped with two vertical sliding doors. Each door is operated by two
hydro-pneumatic cylinders mounted laterally on both sides of the door. Each cylinder
contains an integrated and separated oil system. The operation of the cylinders is
performed by air pressure and the oil system acts as a speed control system. An
adjustable restrictor controls the flow of oil from one side to the other side on each
cylinder, controlling the speed movement of the door. (For servicing of the unit see the
SERVICING INSTRUCTIONS chapter.)
The autoclave is mounted through a recessed wall. The two doors are located in two
separate rooms.
The front door, on the side of the master control panel is in the preparation area, from
where the autoclave is operated and serves for loading the material into the sterilization
chamber. This area is known as the "dirty side." The rear door is located on the "clean
side" and serves for unloading the sterilized material from the autoclave. This side of
autoclave is equipped with secondary control panel (slave).
The sealing of the chamber is achieved through a heat resistant silicone gasket, located
in a groove around the door opening of the autoclave. The gasket is pressed against the
door by steam pressure introduced into the groove behind the gasket.
The interlocking system of the door is based on the following opening conditions:
Both doors cannot be opened at the same time. Opening of one door
automatically locks the other.
A door cannot be opened at the end of the cycle if the chamber temperature is
higher than the preset final temperature.
The electronic circuitry and software programming of the programmable control system
are designed to operate 10 sterilization programs. Three programs are intended for un-
wrapped instruments, four for wrapped instruments and packs, three for slow exhaust
pressure cycles. In addition, there are two test programs: Bowie & Dick Test and the
Leakage Test.
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.
The system is equipped with two temperature sensors,four pressure transducers, five
pressure gauges, and safety devices having the following functions:
Warning!
It is strictly forbidden for any person to enter the service area behind the service
access panels, except the trained technician.
If, for any reason it is necessary to open the service access panel, the person
must shut the system by pressing the emergency switch, withdrawing the key and
keeping the key on him, to prevent accidents and injuries.
The technician must follow the instructions in the SERVICE INSTRUCTIONS,
“Working with power ON in Service Area” Section.
1. Pressure Gauges
2. Emergency STOP Switch
3. Operation Panel
4. Printer
5. Operating Switch
6. Steam Selector Switch
7. Chamber
8. Service Access Panel
2 1
Symbol Description
Utility Specification
Warning!
Do not use the autoclave in presence of dangerous gases and vapors.
2.2 Mounting
Place the autoclave on a suitable level surface, leaving adequate space around it for
operation and service requirements.
Level the autoclave before connecting the utilities.
Utilities
Connect the autoclave to the utility supplies as follows:
Air
Connect the air connection of the autoclave to the compressed air supply of the building
by means of a ¼‖ pipe at 6–8 bar (85–115 psi).
Water
The autoclave is supplied by two water systems:
1. Tap Water
Tap water for the vacuum pump and cooling the heat exchanger;
Hardness should not exceed 0.7–2 mmol/l See also chapter "Water
Quality".
Pressure should be in the range of 2–5 bar (30–70 psi)
Connection to the network by a ½‖ pipe.
2. Distilled or Mineral Free Water
Distilled or mineral free water for the steam generator.
Connect the distilled or mineral free water reservoir to a distilled or mineral
free water supply source by a ½" pipe.
Pressure should be in the range of 2–5 bar (30–70 psi)
See also the Water Quality paragraph!
Attention
Connection of water systems to the autoclave must be performed through "BACK
FLOW PREVENTION SYSTEM" installation as per EN 1717 regulations and local
regulations.
MAN205-0195042EN Rev. A Aug. 2011
Page 11 of 137 pages
Drain
Connect the following outlets directly to the drain funnel. or connect them
through a drain collector pipe of 4-6‖ that should be covered. The drain
system should be vented.
Connect the building steam supply to the autoclave inlet by a ¾" pipe.
The steam supply pressure should be between 3.5–4.5 bar (50-65 psi).
(See also Utilities Table).
The steam trap on the building steam supply should not exceed 2 meters
from the machine.
Warning!
Only a qualified electrician may perform the electrical connections!
The electrical units should not be placed near water sources.
Connect the power cord to the electric box of the autoclave
Note:
Before operating the vacuum pump, make sure that the pump shaft is free and
you can turn it with a screw driver.
Warning!
It is strictly forbidden to enter the autoclave chamber!
If, for any reason (for cleaning, maintenance or if something falls down), it is
necessary to enter the chamber, the person must lock the system by pressing the
emergency switch and take the key with him to prevent accidents and
unauthorized use.
Warning!
It is strictly forbidden for any person to enter the service area behind the service
access panels, except the trained technician.
If, for any reason it is necessary to open the service access panel, the person
must shut the system by pressing the emergency switch, withdrawing the key and
keeping the key on him, to prevent accidents and injuries.
The technician must follow the instructions in the SERVICE INSTRUCTIONS,
“Working with power ON in Service Area” Section.
Adjust the legs of the transfer carriage to equal the height of loading cart to
rails in the sterilization chamber.
Check connection to steam generator. Open the steam. Manually test the
steam valves by over-riding the appropriate solenoid valve. If there are no
leaks, –leave the steam manual inlet taps open.
Run a cycle.
Call for an authorized inspector to test and approve the autoclave; generator
and, assembled system.
Water to the steam generator is supplied by a one-phase pump, from a water reservoir,
which is connected to a source of distilled or de-mineralized water. The electrical system
of the steam generator is located in a separate electric box.
The water level control system consists of three electrodes connected to the GICAR
2DRLHG controller, which commands the operation of the water pump and servo
solenoid valve to switch OFF the heating current in case of lack of water or low water
level.
Use only distilled or mineral-free water for the operation of the generator!
Caution!
It is strictly forbidden to use soft water; this may results in corrosion of the
generator.
Warning!
Only a qualified electrician may perform the electrical connections!
The electrical units should not be placed near water sources.
When servicing the generator, disconnect the all electrical power supplies to the
unit. This is done by switching OFF the main power supply switch, or by un-
plugging the electrical power main supply cords.
It is important to achieve an electrical good grounding connection to the sheet
metal enclosure of the electric box and metal parts of the generator.
The earth installation at the customer’s site must be built in compliance with the
laws and regulations in force, and should meet international electrical safety
standards, and be certified by competent authorities.
RL1
CR1 PS GICAR 2DRLH
24VDC S E
5
10
RL2
Water level too low
RL1
RL2
L N
400 mm
Heaters Power Water
Circuit Breaker
1 3 5 13 A1 1 3 5 13 A1 (OFF)
L1 L3 L5 NO L1 L3 L5 NO
3 3
Fault Light
45
46
KM2 KM1
Fault
2 4 6 14 2 On Generator
4 6 14
T2 T4 T6 NO A2 T2 T4 T6 NO A2
Heater 2
electric box
Heater 1
Trip Coil
400 mm
If this happens, do not try to correct the fault yourself, but call for assistance.
Generator electrical layout for
2 sets of heater with single phase ES1G08-0001-SP
Page:1 Marchel N.
3.1.2 The Water Pump for the Steam Generator 22.8.10
See page 4
The supply line of the pump is connected to the upper water reservoir filled with distilled
or mineral-free water and mounted on side of the autoclave.
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, when the water level drops below the
lower level limit.
Front of Generator
Dimensions in mm
The long electrode which is continuously immersed in the water, acts as a reference and
is connected to ground.
The medium electrode (LOW level electrode) controls the water heaters. When it stops
sensing water, the GICAR controller stops the current to the water heaters. When it
senses water, the GICAR controller restores current to the water heaters.
The short electrode (HIGH level electrode), controls the water pump. When it senses
water, the GICAR controller stops the current to the water pump and simultanausly
closes water supply shut off valve. When it stops s ensing water, the GICAR controller
restores the current to the water pump and simultanausly opens water supply shut off
valve.
Electrode Electrode Electrode
Low Low low high
Reference (heater) (water )
1
2 3
44 45 46
S S S S S S
R M m R M m
1 1 1 2 2 2
S E
RL1
GICAR 2DRLH
S E
RL2
RL1
RL2
L N
VAC
Heater Water
Pump
D1 L1 L2 L3 D1 L1 L2 L3 L1 L1
S S S S S S
6 3 6 3 4 4
R Mm R Mm R/L1 S/L2 T/L3
TC Test 1 1 1 2 2 2
S E
MAN205-0195042EN Rev. A
RL1
CR1 PS GICAR 2DRLH
24VDC S E
5 RL2
9
TC2
PLC CB2 TC1
PLC CB1 CB3 CB4
PLC 10
CB CB CB
RL1
RL2
L N
8
D2 T1 T2 T3 D2 T1 T2 T3 T1 T1
Main Switch 1
NO
400 mm
3 ph To Water
To control panel Pump 1 3 5 13 A1 1 3 5 13 A1
L1 L3 L5 NO L1 L3 L5 NO
3 3
35
36
37
38
39
40
41
42
43
44
45
46
PE N PE N L1 L2 L3 PE N L2
KM2 KM1
Fault
2 4 6 14 2 4 6 14
TB2 TB4 T2 T4 T6 NO A2 T2 T4 T6 NO A2
TB3
200 mm 400 mm
GENERATOR ELECTRICAL LAYOUT
Page: 1 Marchel N.
See page 4
22.8.10
Rev No. Prepared by: Approved by: Q. C.
From: 4
Yuval S.
ISO A3 01
22.8.10
Aug. 2011
Preparation By: Description Date Rev. No ECO
See page 1
MAN205-0195042EN Rev. A
Q0 CB1 KM1
Legend:
L1 T1 L1 T1 L1 T1
R/L1
L2 T2 L2 T2 L2 T2
S/L2
L3 T3 L3 T3 L3 T3
T/L3
TC1<
C1
N
L1
Heaters 1
PE/GND
1. HEATERS = 208V /6000W
L2
CB2 KM2
TB1 L3
L1 T1 L1 T1
2. KM1 & 2 = CONTATOR: DILM65
TB2
L2 T2 L2 T2
44. QS1 = PANEL SWITCH: 3 PH 125A
L3 T3 L3 T3
Control C2
Panel
GENERATOR POWER ELECTRICAL DIAGRAM
Heaters 2
PE/GND
Aug. 2011
Preparation By: Description Date Rev. No ECO
See page 1
~ VAC
Q0/L1 N
+ -
TB1 24VDC
Pressure Temperature Steam
Cut off Level Elec. Low Cut off Pressure Heater 1
CB4 Air Supply Water Supply Level Elec. High
RL1 41 40
A1 A2 Pressure Pressure/Float RL2 Water Relay
L T
38
C1
32 33 36 37
4A
42 43 39
R1
NC
MAN205-0195042EN Rev. A
TC Test Heater 2
34 A1 A2
C2 Water Valve
35 1
Heaters Lamp 2
Trip coil 1
D1 D2
TC1
Trip coil 2
Electrode Electrode Electrode
D1 D2 Low Low low high
TC2
Reference (heater) (water )
Fault Alarm 1
2 3
44 45 46
Power
S E
RL1
PS L N
Q0/L2 L N
24VDC
2 VAC
36 33 35
Water
Heater Pump
GENERATOR CONTROL ELECTRICAL CASCADE DIAGRAM
Water Pump
CB3 R1
L T TB3 TB3
M
NO Description: Job No. Scale: Drawing No.
4A Generator Control Electrical Cascade Diagram
for 2 sets of heater with neutral ES1G08-0001-N
Water Lamp
Design: Drawing: Quant./Unit: Quant./Job: Cat. No.
Page: 3 Marchel N.
Aug. 2011
3.2 The Piping System
The piping system of the autoclave consists of air-operated valves, which control the
condensate and steam flow in and out of the chamber, operate the vacuum, and the air
inlet valve. The air pulses to the pneumatic valves are transmitted through solenoid pilot
valves, operated at 24VDC.
The functions of the valves are as follows:
Steam to jacket (91) – introduces steam into the jacket to accelerate the heating of the
chamber and to maintain a stable and uniform temperature in the chamber during the
sterilization and drying stages.
Steam inlet valve (93) – introduces steam from the jacket into the chamber, for heating
and maintaining the chamber temperature during the sterilization phase.
Building steam inlet valve (90) – introduces steam directly from the building source
into the system. This valve is controlled by an ON-OFF-ON switch on the front panel.
Generator steam inlet valve (92) – introduces steam from the steam generator into the
system. This valve is controlled by an ON-OFF-ON switch on the front panel.
Air inlet valve (43) – introduces filtered ambient air into the chamber at the end of the
cycle to break the vacuum and enable the opening of the door.
Fast exhaust and vacuum valve (75) – This valve performs two functions:
1) To exhaust the steam from chamber.
2) To connect the chamber to the vacuum pump to create vacuum in the
chamber in the air removal and drying stages.
In both actions, exhaust and vacuum, the flow path of the fluids is through the condenser
(heat exchanger) and the vacuum pump to drain.
Condensate valve (74) – evacuates the condensate from the chamber during heating
and sterilization phases and isolates the chamber from the drain pipe, during vacuum
generation. It operates like a slow exhaust valve at the end of slow pressure programs.
Water to vacuum pump valve (15) – is connected to the tap water reservoir and
supplies the water required by the operation of the vacuum pump.
Water to heat exchanger valve (12) – introduces tap water to the heat exchanger to
cool the fluids at the inlet of the vacuum pump.
Pressure to gasket valves (94 1-2) – control the steam pressure to the door gaskets.
When the doors are closed, steam enters through the valves into the grooves behind the
gaskets pushing them against the doors to seal the chamber.
Mineral free water inlet valve (21) – allows distilled or mineral free water from the
pump and prevents the return flow of hot water from the steam generator to the
reservoir.
Note:
The valve numbers are in accordance with the valve numbering list and piping
diagram.
1. RT112 pressure switch – (prevents the opening of the door if there is pressure
in the chamber)
2. SMS VM8 End switch– (prevents the pressurizing of the chamber and the door
gasket if the door is not closed)
3. ALCO pressure switch – (prevents the operating of the door if there is no
vacuum in the door gasket)
The autoclave is fitted with four pressure transducers for controlling & monitoring:
1. Chamber pressure – (control, display, and printout)
2. Jacket pressure – (control and monitoring)
3. Door 1 gasket pressure – (control and monitoring)
4. Door 2 gasket pressure – (control and monitoring)
The terminals at the connector of the device are 1 (+24V) and 2 (OUT) to the controller
output.
ELECTRIC
CONNECTIONS
Warning!
Only authorized electricians are allowed to install or attend the electrical system!
Description of the Electrical Equipment (see Steam Generator and Electrical
Drawings)
Warning!
It is strictly forbidden for any person to enter the service area behind the service
access panels, except the trained technician.
If, for any reason it is necessary to open the service access panel, the person
must shut the system by pressing the emergency switch, withdrawing the key and
keeping the key on him, to prevent accidents and injuries.
The technician must follow the instructions in the SERVICE INSTRUCTIONS,
“Working with power ON in Service Area” Section.
Each ADC maintains at least 3 temperature sensors (PT100), and 3 pressure sensors
(4–20mA).
All connections to the main board are via rigid connectors for quick and efficient
dismantling.
Digital Inputs
The digital inputs are 0/1:
Open/close for door positions
Safety cut-off switches
Pressure cut-off switches
Switches for water level
The input voltage is 24VDC. The input is 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 pumps and
heating elements.
Each output is up to 2A, however all the outputs together will not have a capacity higher
than 110 W.
The command voltage is 24 VDC, but it can vary in the range of 10–30VDC.
3 Serial Ports
The control system contains 3 serial ports (1optional) according to the following
specifications:
2 Serial Ports for the connection of up to 2 command panels.
1 Serial Port connected to an external PC computer (RS232/485).
1 Serial Port (optional)
GICAR
To Eliwell
+24V
MAN205-0195042EN Rev. A
Sm 1 2
GICAR DRLH
Safety Interlock 2 (SI 2)
PLC
RL
Power 02
Supply From output-13 to Relay
SAFETY INTERLOCK DEVICES
+24V
Eliwell
IC912
1 2 3 6 7 10 11 12
Aug. 2011
Page 35 of 137 pages
Aug. 2011 MAN205-0195042EN Rev. A
T
S
R
GND
P1-25
3x208V/60Hz
PKZM 0-6.3
Vacuum Pump
DILM12
1
EMERGENCY STOP
PS 5VDC
2
To Panel 2
CB1
92
90
2
On/Off Switch
RPD-65D
Power Supply
Power Supply
Safety
Interlock
24V
RT112
5V
ANL IN
GND
PANEL2
PANEL1
OPTION
53-2
COMPUTER
94-2
TUTTNAUER
6
ISO A4
39-2
5
Close door 2
PT100-1CONDENSE
PT100-2 CONDENSE
4
Open door 2
From 1
Page 1
PT100-5COOLING DRAIN
ALCO 3
Description:
38-2
PT100 Sensors
Out 24
2
Out 23
53-1
Vacuum from gasket door 1 1
Out 22
94-1
Out 21 24V
Steam to gasket door 1 7 Press Door2 Seal
Out 20 6
39-1
Out 19 5
REV. No. 00
Close door 1
Yan. S
4 Press Door1 Seal
Out 18
Design: 17.07.2011
3
4-20mA Sensors
38-1
INPUT 16 Press Chamber
Out 15 INPUT 15
INPUT 14
Out 14 INPUT 13
Out 13 INPUT 12
Yan S.
Drawing for horizontal autoclave with two sliding doors
12
INPUT 11 Safety door2 switch
Drawing: 17.07.2011
Feed Water to Cooling Drain Out 12 INPUT 10 Safety door1 switch
Out 11 INPUT 9
75
Exhaust to Vacuum Pump Out 10 INPUT 8
Limit door2 sw.
Job No.
DIGITAL OUTPUTS
Out 9 INPUT 7
INPUT 6
74
Quant./Unit:
Slow Exhaust to Drain Float vac.pump sw.
INPUT 5
DIGITAL INPUTS
Out 8
INPUT 4
Marchel. N
Out 7 INPUT 3
91
Steam Inlet to Jacket Limit door1 sw.
Scale:
INPUT 2
Quant./Job:
Out 5
93
Steam Inlet to Chamber Out 4 GND
GND
CAT2007
Out 3 5V
Q. C.
43
Out 2 5V
Cat. No.
Filtered Air Inlet 24V
8 7 6 5 4 3 2 1
Out 1 GND
H02SF01
Drawing No.
15
Water to Vacuum Pump
ELSALVADOR11001809
ELECTRICAL CONTROL SYSTEM DRAWING
3.8 Water Quality
Physical Characteristics and Maximum acceptable contaminants levels in
water or steam, for steam generator and sterilizers
(According to EN 285:2006).
Contaminants in
Contaminants in
condensate at
water supplied to
generator steam inlet to
sterilizer
Evaporate residue ≤ 10 mg/l N/A
Silicate (SiO2) ≤ 1 mg/l ≤ 0.1 mg/l
Iron ≤ 0.2mg/l ≤ 0.1mg/l
Cadmium ≤ 0.005 mg/l ≤ 0.005 mg/l
Lead ≤ 0.05 mg/l ≤ 0.05 mg/l
Rest of heavy metals
except iron, cadmium, ≤ 0.1 mg/l ≤ 0.1 mg/l
lead
Chloride (Cl) ≤ 2 mg/l ≤ 0.1 mg/l
Phosphate (P2O5) ≤ 0.5 mg/l ≤ 0.1 mg/l
Conductivity (at 25°C) ≤ 5 µs/cm ≤ 3 µs/cm
pH value (degree of
5 to 7.5 5 to 7
acidity)
Hardness (Σ ions of
≤ 0.02 mmol/l ≤ 0.02 mmol/l
alkaline earth)
Appearance Colorless, clean, without sediments
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.
Tap Water supply
Maximum hardness value 0.7-2.0 mmol/l
Note:
The use of soft water is strictly forbidden!
4.1.1 KeyPad
STANDBY
The ON/ST.BY key is located on the top right side of the panel. Press this
key to light up the operation panel. When there are 2 panels, both light up
even though only one was operated.
3 Command Keys
F1- 3: Functions 1- 3
F1 F2 F3
These keys are found under the display. The function to be performed is displayed
above each key.
10 Digit keys
These keys are used for 2 purposes:
Under normal working conditions the program option is used. Press on the number key.
For example, no. 3 selects program 3.
Under the display mode, the keys are used as number keys to enter a code or a
number.
UP/DN Keys
Under normal working conditions, they are used to browse through the
different cycles.
Under set-up mode they change numeric value or move the display to the
next screen.
STOP Key
This key is active while the autoclave is in operation. Pressing STOP at
any stage of the cycle stops the operation.
RUN/FAIL LEDs
The operation panel contains 2 small LEDs which 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 by the ST.BY key,
the RUN LED will flash for 1/2 a second for every 2 seconds indicating that the system is
still ON. The FAIL LED (red) lights when there is a problem with the system.
Note:
Temperature and pressure measuring units differ according to the country of
operation. Temperature and pressure are displayed in both ºC or ºF and kPa or
psi, respectively.
The CAT2007 display consists of 4 alphanumeric rows with 20 characters in each row
(see Figure below)
First Row
First 3 characters define the Cycle no. (ranges from 1–12)
8 characters define the cycle name.
The 5 final characters at the right end of the row are allocated for displaying the status of
the autoclave or the stage of the cycle in operation.
First Row
1, 2, 3 Un-wrapped 134
4, 5, 7 Wrapped 134
6 Wrapped 121
8, 9, 10 Slow Exhaust 121
11 B&D test 134
12 Leak test —
Second Row:
This row displays the temperature in the chamber, pressure in the chamber, and jacket
pressure.
Second Row
Third Row:
This row is used to display messages to the operator such as DOOR1 OPEN.
Third Row
Fourth Row:
On the bottom row, the names of the commanding keys appear. Under the display there
are three keys without symbols or names. These keys 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 pre-vacuum, to
display the stage of the pulse, such as puls1 – pump to 21K.
24 - Door2 Gasket Low If whilst opening Door #2 you do not achieve the proper
Vacuum vacuum in Gasket2.
This message is a result of a safety mechanism indicating
that if during the pre-vacuum stage, drying stage, vac. test or
leak test it is revealed that the lower float switch in the
25 - Vac Res. Empty
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
27 - First Close Door
IN/OUT Test while the door is open.
Informative Messages
If the system is not ready it will not allow you to start a 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 following screen
appears:
A cycle can only be selected in Stand By from the Stand By / Ready screen which
displays the cycle number and name in the top row.
To select a cycle:
1. Press the UP/DN keys to change the cycle where pressing UP moves to the
next program and pressing DOWN moves to the previous program.
2. Press on a number; press key 4 to select program 4
Show Parameters
After selecting the cycle, when pressing the SHOW command key the following screen
is displayed:
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 12 – Leak Test.
There is enough distilled or mineral free water for the steam generator.
2. Check that all the valves and outputs, including LEDs on the panel are turned
OFF.
6. Check that the two LEDs on each panel are turned OFF, the message deleted
and the system moves to into the Stand By Mode.
Testing all the outputs. Each output is turned ON one at a time. The
output passes to ‗ON‘ for a maximum time of 15 seconds or until the
UP key is pressed.
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 PC.
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.
English Ø
German 1
French 2
Spanish 3
This autoclave has two door, press ØØØ2. Press ENTER, and the system moves to the
next screen.
Door Type
There are 3 different types for autoclaves – Manual Door, Automatic Hinged Door, or
Automatic Sliding (horizontal or vertical) Door.
In this autoclave, the doors are Vertical sliding doors; the door type is (ØØØ2). Enter
these values either through the UP/DN keys and then press ENTER, or enter the digits
whereby the screen will automatically progress to the next display after entering the
fourth digit.
Atmospheric Pressure
The standard atmospheric pressure at the sea level is 100 kPa and for every 100m
above sea level the atmospheric pressure drops by 1kPa, and for every 100m below sea
level the atmospheric pressure increases by 1kPa. For example, at an altitude of 2500m,
the Atmospheric Pressure will be 75 kPa.
(The standard atmospheric pressure at Sea Level is 14.5psi. For every 1000ft. above
sea level, the atmospheric pressure drops 0.45psi, and for every 1000ft below sea level,
the atmospheric pressure increases 0.45psi.)
When a door of the autoclave is open then set Atm. Pres. The parameter entered into
the program memory will serve as reference for correct pressure control and monitoring.
If pressure is set correctly, then press ENTER and the next screen appears. If pressure
needs to be altered, this may be done either through the digital key or the UP/DN keys.
F – 0 Mode
This mode enables F – 0 calculations, the processing being based on data fed by two
temperature sensors. One mounted in chamber and one on the condensate pipeline.
The F - 0 calculations is performed for cycles with sterilization temperatures in the range
of 101ºC–134ºC (215ºF - 273ºF), especially used in programs 8–10.
F – 0 = 0 (unable)
F – 1 = total heating time + total cycle time + cooling time.
F – 2 = compensate 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 – 0 = determines the temperature at which F – 0 calculations should begin.
1. Press CLEAR or ENTER before entering the code to return to the Stand By
screen; the RUN & FAIL LEDs are lit.
2. Enter the correct code via the UP/DN keys.
3. Press ENTER to proceed to the next screen.
4. Press the UP/DN keys to change all parametric values.
CODE 1 OR 11 PARAMETERS
STE Temp – Required sterilization temperature for the process
Entry code 1
Resolution 1º
Minimum value 105ºC (221 ºF)
Maximum value 137ºC (278 ºF)
STE Time – Required sterilization time for the process
Entry code 1
Resolution 1 minute
Minimum value 1 minute
Maximum value 99 minutes
Dry Time – Required drying time for the process
Entry code 1
Resolution 1 minute
Minimum value Ø minutes
Maximum value 99 minutes
Ex Mode – The method for exhausting the steam at the end of the process
Entry code 11
Ex Mode
Fast Ex 1
N.A. 2
Slow Ex. (waste) 3
Slow Ex. (liquids) 4
Cooling with compressed air 5
Cooling with water circulation 6
EndTemp – Ending Temperature (Exhaust Stage)
Defines the temperature at which the process ends for opening the door.
Entry code 11
Resolution 1º
Minimum value 40ºC (104ºF)
Maximum value 137ºC (278ºF)
PulsNum. – No. of pulses in the pre-vacuum stage
Entry code 11
Resolution 1
Minimum value 1
Maximum value 10
VacDip1 – Vacuum value in the first pulse
Defines the vacuum value in pulse No.1 of the pre-vacuum stage
Entry code 11
Resolution 1 kPa (0.1 psi)
Minimum value 1 kPa (0.15 psia)
Maximum value 75 kPa (10.8 psia)
Entry code 13
Resolution 1
Minimum value 1
Maximum value 5
If the pressure in the chamber is higher than 115 kPa (2.7 psig), the door will not open.
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 passes to the Exhaust stage,‘ it will display ‗EXH TO 100K‘.
Help:
If at any stage there is a problem, you can turn the system can be OFF at the power
switch. Turn ON the power again while pressing STOP till you hear a long buzz. After
loading, the screen lights with the message below.
The display returns to the ST.BY screen and you can continue.
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 plain paper with 24 characters per line and contains the
following information:
Software version
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.
1. Press the paper cover open button, and open the paper cover. Handle the
paper cutter carefully not to cut your hand.
2. Set a paper roll as shown in the figure.
3. Close the paper cover by pressing both ends of the cover with the tip end of
the paper emerging from the cutter.
Maintenance
Wipe off the soiling on the printer surface with a dry soft cloth with a weak neutral
detergent. After that, wipe the printer with a dry cloth.
Test points
In the test print mode, characters printable with the printer (ANK, KanJi) and bar code
are outputs. Turning power ON with the FEED IN signal kept low triggers the test print.
Caution!
Never disassemble the printer. Failure to follow this instruction may cause
overheating or burning of the printer or the AC adapter. Or an electric shock,
which may lead to fires or accidents.
Never use the printer in a place of extreme humidity or any place where it can
possibly be splashed by any liquids. If any liquids get into the printer, it could
lead to fire, electric shock, or other serious accidents.
Never touch the thermal head immediately after printing because it becomes very
hot. Make sure that the thermal head is cool before setting papers or cleaning the
thermal head.
The autoclave is equipped with 12 programmable sterilization programs and two test
programs. The test programs are pre-set by the manufacturer in such a way, that their
parameters are not changeable.
Following are the names, relevant programs with related temperatures of the 12
sterilization cycles and 2 test programs.
1, 2, 3 Un-wrapped 134
4, 5, 7 Wrapped 134
6 Wrapped 121
8, 9, 10 Slow exhaust 121
11 B&D test 134
12 Leak test —
Caution!
Care should be taken to preserve the sterility of un-wrapped instruments
in a non-sterile environment.
Program 1, 2, 3 for Un-wrapped goods 134ºC (Process Sample)
134°C 3 min
134°C/ ~305 kPa
160 kPa
Ex Mode 1
104°C/ ~115 kPa
100 kPa
50 kPa
25 kPa
0 kPa
1 min
134°C 7 min
160 kPa
Ex Mode 1
104°C/ ~115 kPa
100 kPa
50 kPa
25 kPa
0 kPa
15 min
121°C 15 min
121°C/ ~205 kPa
160 kPa
50 kPa
25 kPa
0 kPa
15 min
50 kPa
25 kPa
0 kPa
160 kPa
Ex Mode 1
104°C/ ~115 kPa
100 kPa
50 kPa
2 min
25 kPa
0 kPa
Performance Description:
A vacuum is drawn in the chamber down to 18 kPa. At this stage all valves and motors
are closed. A period of 5 minutes is counted to enable stabilization of pressure. During
the next 10 minutes the pressure is monitored.
The acceptable change of pressure during these 10 minutes is 1.3 kPa.
100 kPa
50 kPa
25 kPa
0 kPa
5 min 10 min
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.
3. In case carbon steel instruments are used with stainless steel trays, the tray
should be lined with a towel or paper wrap before placing the instrument.
There should be no direct contact between the carbon steel and the stainless
steel trays.
4. All instruments must be sterilized in an open position.
5. Place a sterilization indicator strip in each tray.
6. Once a week use a biological spore test indicator in any load to ensure
sterilization.
7. Make sure that all the instruments remain apart during the sterilization cycle.
8. Empty canisters should be placed upside-down in order to prevent
accumulation of water.
9. Do not overload sterilizer trays. Overloading will cause inadequate sterilization
and drying.
10. Allow a distance of approximately 2.5 cm (1") between trays to permit
circulation of steam.
11. Wrapped instruments should be packed in material which promotes drying,
such as autoclave bag, autoclave paper and muslin towels.
Attention
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).
Caution!
It is strictly forbidden to load or un-load the loading cart, if the transfer carriage is not
connected by the hooks to the autoclave, and the brakes are not applied.
When loading the materials to be sterilized into the chamber, observe the rules
described in this chapter.
Do not overload the loading cart or the shelves as this can have adverse effects on the
results of the sterilization and drying. Leave space between the packs or wrapped
instruments to allow complete removal of air pockets in the air removal stage, and for
free penetration of steam in the heating and sterilization stages.
Securing hooks
Transfer Carriage
Loading Cart
7.2 Un-loading
1. When the buzzer signals the successful completion of a cycle, open the door
and let the load cool down for several minutes.
2. Hook the transfer carriage firmly to the autoclave, apply the brakes, and roll the
loading cart out of the chamber.
3. Once the loading cart is firmly on the transfer carriage and locked into place,
release the hooks and the brakes, and take the transfer carriage or the
containers aside to cool down.
4. Allow the load to cool down in an area with minimum passing traffic (to avoid
the possibility of touching the hot load), and without air movement (air
conditioning, etc.). Do not touch the hot load. Hot loads absorb moisture and
may absorb bacteria from a hand.
5. Do not transfer a hot load to metal shelves for cooling. Perform a visual
inspection to ascertain that sterilizing indicators have made the required color
change, and that the load is dry.
Warning!
It is strictly forbidden for any person to enter the service area behind the service
access panels, except the trained technician.
If, for any reason it is necessary to open the service access panel, the person
must shut the system by pressing the emergency switch, withdrawing the key and
keeping the key on him, to prevent accidents and injuries.
The technician must follow the instructions in the SERVICE INSTRUCTIONS,
“Working with power ON in Service Area” Section.
Warning!
Do not operate the autoclave in the presence of dangerous gases and vapors.
Observed the manufacturer recommendations sterilization data for each type of
material.
Observe the manufacturer recommendation sterilization data each type of material.
Starting the autoclave
1. Check that the feed water manual valve is open.
2. Check that the compressed air manual valve is open, and compressed air is
available.
3. Choose the appropriate steam source, and check that the steam inlet manual
valve is open.
4. If the internal generator is to be used, check the generator is connected to the
electrical supply and working properly. See ―Operation & Maintenance manual‖
for starting and operating the steam generator.
5. Power the autoclave by turning ON the main power switch.
6. Observe the gauge and see, that the generator reaches working pressure.
7. Check that the jacket pressure gauge, reaches 2.4 bar (35 psi).
Running a sterilization program
1. Open the door by pressing the F3 key (the right button on the row below the
display); the word "OPEN" appears on the lower row of the screen indicating
that the door can be opened. The message "OPENING DOOR – WAIT" is
displayed on the third row. The door slides down to the lowest position.
2. Load the sterilizer.
3. Close the door by pressing the F3 key, when the word "CLOSE" appears in the
lower row of the screen 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.
4. Select the required program, then press START.
When a sterilization program is running, the LED RUN lights up on the control
panel.
5. At the end of the cycle a buzzer sounds and the word "END" is displayed.
Press STOP to cancel the buzzer. Open the door by pressing the F3 key while
"OPEN" is displayed above this key.
6. Take out the sterilized material from the chamber following the steps
mentioned in the ‗Un-loading‘ paragraph.
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. At the end of the cycle an interrupted
sound is heard. Press the STOP key to cancel the alarm.
1. Press STOP.
3. Log the displayed message in the autoclave log book or any other appropriate
document.
4. If you cannot solve the problem, turn OFF the autoclave and call for service.
Note:
Verify that the pressure in the chamber is atmospheric pressure. Do not attempt
to open the door if the pressure in the chamber is above atmospheric pressure.
1. Press the STOP key; the autoclave automatically goes through a shut down
sequence. The unit will either open the drain valve to remove pressure form
the chamber or open the vacuum break valve, depending upon the phase of
the cycle.
2. The autoclave will signal the operator that the cycle has been aborted and will
advise the operator when the door can be opened. (see above)
Note:
When a power failure occurs, the autoclave holds the cycle at that point where
the power was lost. The system stays in the locked down safe mode until the
power is restored. At the power restoration the controller follows the abort
sequence described above.
CAUTION!
DO NOT ATTEMPT TO OPEN THE DOOR UNTIL NOTIFIED THAT THE ABORT
SEQUENCE IS COMPLETE. IF THE CONTROLLER DOES NOT INDICATE THAT
THE SEQUENCE IS COMPLETE, DO NOT ATTEMPT TO OPEN THE DOOR.
CONTACT YOUR TUTTNAUER TRAINED AND CERTIFIED AUTOCLAVE
TECHNICIAN.
Warning!
It is strictly forbidden for any person to enter the service area behind the service
access panels, except the trained technician.
If, for any reason it is necessary to open the service access panel, the person
must shut the system by pressing the emergency switch, withdrawing the key and
keeping the key on him, to prevent accidents and injuries.
The technician must follow the instructions in the SERVICE INSTRUCTIONS,
“Working with power ON in Service Area” Section.
Warning!
These service instructions are for the use of qualified personnel only! To avoid
electric shocks, do not perform any servicing other than that specified in the
operating instructions unless you are qualified to do so. Refer all servicing to
qualified service personnel.
When servicing the autoclave, and/or opening any service panel, disconnect the
all electrical power supplies to the unit. This is done by switching OFF the main
power supply switch, or by un-plugging the main electrical power supply cords.
Warning!
It is strictly forbidden for any person to enter the service area behind the service
access panels, except the trained technician.
The technician must follow the instructions in the SERVICE INSTRUCTIONS,
“Working with power ON in Service Area” Section.
MAN205-0195042EN Rev. A Aug. 2011
Page 79 of 137 pages
9. MAINTENANCE OF AUTOCLAVE
9.1 Preventive and Periodical Maintenance
1. Clean the strainer at the bottom of the chamber.
Before each 2. Verify that the door gasket and the surface that the
cycle gasket is pressed on are clean.
3. Keep the door closed between sterilizing cycles.
1. Clean the door gasket every day with a soft cloth.
2. Before the first operation of the day, warm up the jacket
for at least 20 minutes with the door closed, even if the
READY LED is lit up.
3. Keep the door closed between sterilizing cycles.
User
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
User
steps:
a. Remove the door gasket, and thoroughly clean the door
6 months
gasket and the groove.
b. Leave the door gasket out for the weekend.
c. Before start of day/shift after the weekend, re-place
the door gasket according to the instructions in the
―Replacing the Door Gasket― section.
Warning!
It is strictly forbidden for any person to enter the service area behind the service
access panels, except the trained technician.
If, for any reason it is necessary to open the service access panel, the person
must shut the system by pressing the emergency switch, withdrawing the key and
keeping the key on him, to prevent accidents and injuries.
The technician must follow the instructions in the SERVICE INSTRUCTIONS,
“Working with power ON in Service Area” Section.
Attention!
After every repair or dismantling the enclosure, the autoclave should pass two
electrical safety test by the qualified Service Engineer. The following shall be
performed:
After performing these tests, the Service Engineer should complete and sign the
Work Order and the Log Book.
Warning!
It is strictly forbidden for any person to enter the service area behind the service
access panels, except the trained technician.
If, for any reason it is necessary to open the service access panel, the person
must shut the system by pressing the emergency switch, withdrawing the key and
keeping the key on him, to prevent accidents and injuries.
The technician must follow the instructions in the SERVICE INSTRUCTIONS,
“Working with power ON in Service Area” Section.
1. Control unit not initialize. 1.1 The control circuit 1.1 Check and switch on
No display and lights on the breaker switched off. the circuit breaker.
front panel.
1.2 The power switches 1.2 Replace the defective
on the front panels of switch.
the autoclave or on the
steam generator are
defective.
2. Steam generator does not 2.1 Water pump defective 2.1 Repair or replace
operate. or blocked. pump. Replace motor.
1. Steam 1.1 No power from the building 1.1 Check the reason for no
generator does source. power supply from the
not start. building.
1.2 Generator Circuit breakers
1.2 Turn ON the circuit
(1ph & 3ph) are OFF.
breakers (1ph & 3ph)
1.3 Trip coil is activated (no power
1.3 Check the interlocks status.
feed)
1.4 Water level in the generator is 1.4 No water inlet, See Section
low. No.2 below.
2. Water is not 2.1 The water pump is defective or 2.1 Check, repair or replace
filled into the blocked. the pump.
tank. 2.2 The water inlet solenoid valve 2.2 Check power on solenoid
does not open. contacts or, repair/replace
the valve.
2.3 Check for short circuits, or
2.3 The circuit breaker in the
circuit breaker is defective.
water pump motor circuit trips
Replace the circuit breaker,
OFF.
or fix short circuit.
2.4 Check wires connectivity
2.4 The GICAR water level between the electrodes
controller or the electrodes is and the water level
defective. controller or replace the
defective electrode or
electronic board.
2.5 Replace the circuit Relay.
2.6 Check and switch ON the
2.5 The circuit Relay is defective. circuit breaker of the
2.6 The circuit breaker of the control circuit.
control circuit is OFF or
defective.
3. Steam pressure 3.1 The pressure switch is faulty 3.1 Check the pressure
does not or incorrectly set. switch, set it correctly or
increase or replace if faulty.
increases too 3.2 The circuit breakers in the 3.2 Check the cause and
slowly. heater circuits are switched switch ON the circuit
OFF. breakers.
3.3 The water level control system 3.3 Check and replace the
is defective. defective electrode or
GICAR controller.
3.4 The heater contactor is 3.4 Check and replace the
defective. heater contactor.
3.5 Heaters are burned out. 3.5 Replace the damaged
heaters; check if the
water level is sufficient.
3.6 There is a leakage in the 3.6 Tighten or replace piping
safety relief valve caused by connections, fix or
loose or defective fittings, or replace the safety valve.
by blockage.
4. Steam pressure 4.1 The pressure switch is faulty 4.1 Set the pressure switch
goes up beyond or set incorrectly. correctly or replace if
the set control faulty.
point. 4.2 The heater contactor is stuck. 4.2 Replace the heater
contactor.
5. The safety valve 5.1 The steam pressure is higher 5.1 Check cause and
blows. than the working pressure. remedy it, See section 4
above)
5.2 The safety valve is defective. 5.2 Check and replace the
safety valve.
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
Release pressure on the outlet side of the pump before doing any maintenance
work.
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.
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.
CONDITION A CONDITION B
Appliance Potential Time Potential Time
Rating Volts Seconds Volts Seconds
Less than 100 600 1
100 – 130 volts 1000 60 1200 1
210 – 240 volts 1480 60 1780 1
To set the pressure in which the heating elements turn OFF, turn the bronze
color knob. Turn it clockwise to decrease pressure and counterclockwise to
increase the pressure.
To set the pressure in which the generator restarts (i.e. the pressure
differential between the turn-off and the turn-on pressures) turn the black color
pressure switch knob. Turn it clockwise to decrease pressure and
counterclockwise to increase the pressure.
The pressure switch will be set to an output steam pressure of 3.5 -4 bar.
To set the cut-off pressure, turn the bronze-colored pressure switch knob. Turn
it clockwise to decrease pressure and counter-clockwise to increase the
pressure.
Reset
lever
Turning off
pressure
Cut-off
Differential
pressure
pressure
Front of Generator
Dimensions in mm
Front of Generator
Dimensions in mm
Disconnect the steam generator from the electrical source. Release the steam pressure
from the autoclave and the steam generator.
1. Flush the water out of the steam generator then close the drain valve.
2. Remove the heaters cover.
3. Remove the wire connections from the heaters.
4. Unscrew the heaters and remove them from the front plate of the
generator.
5. Replace new heaters. Ensure that they are tightened well in order to
avoid leakage.
6. Reconnect the wire connections.
7. Replace the heaters cover.
8. Test the steam generator.
Heaters
Glass tube
The vacuum pump could get locked after a prolonged idle period.
Further described, is the procedure to follow in order to unlock and restore the normal
operation of the pump.
1. When the pump is operated for the first time, check if it works normally.
If not, stop the electric current immediately.
2. Do not open the pump and by no means, try to free the rotor shaft, by
forcibly rotating the impeller, this can provoke an irreversible damage to
the pump.
3. Further described is the way to proceed, for restoring the normal
operation of the pump.
a. By means of a screwdriver, rotate in clockwise direction the shaft of
the pump on which the cooling fan of the motor is mounted.
The shaft will be unlocked and the pump is ready for operation.
b. If it did not help, unscrew the pipes connected to the pump and pour
in a quantity of 200ml. of edible vinegar available at any grocery
shop.
Leave the pump in this situation for ½ - 1 hour.
c. By means of a screwdriver, rotate the shaft of the pump on which the
cooling fan of the motor is mounted in a clockwise direction. The
shaft will be unlocked and the pump is ready for operation.
NUT TP FUNCTION
TP1 GND
The programming of the calibration procedure is almost identical for both temperature
and pressure. Calibration 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 of 20ºC-150ºC (68ºF-302ºF).
The pressure circuit is also linear and has an output of 100mV-2400mV for a pressure
range of 0-400 kPa. (0 -58 psi).
The measuring at the A/D is void for values higher than 2400mV or lower than 100mV.
Even though the precision of the components of the circuit is 1%, the acceptable
deviation can reach 5%, therefore calibration is necessary.
The system has a non-erasable memory in which the OFFSET and GAIN data of the
sensors are stored. This data may be inserted into the system, through either
programming or directly through the autoclave.
READ
Y
313
ACTUAL
PRESURE
133
X
V1 V2
a INPUT FROM SENSOR
The calibration method enables the insertion of this data into the system in order to
perform the automatic correction of the OFFSET and GAIN.
Before calibrating it is recommended to find two points that have to be inserted into the
system (temperature or pressure).
Return to the ST.BY screen and select the OPTION command key.
The word CALIB is displayed above the middle command key. Press the middle key and
the same screen for entering the SETUP code will appear.
Enter the correct code via the digital key; the system begins displaying the calibration
options.
Note:
1. If the code is not entered within 15 seconds, the display returns to the
ST. BY screen.
2. If the code is incorrect it will return to the ST.BY screen
3. In all screens following the code entry screen, the middle command key
is CLEAR and the right key is ENTER. Pressing on either of these keys
opens up the next screen.
4. The values in all the following screens can only be changed via the
UP/DN keys. When the correct value is displayed, press ENTER and
the system will progress to the next screen.
Once the entry code has been entered, the following screens appear:
Temp 1:
Temperature of sensor 1
This screen requires a code. Press the UP key once to enter the code value ØØ1 and
press ENTER.
A screen displaying 4 Temp values appears:
A100 (140) R100 (140)
A130 (226) R130 (226)
Press the right button (F3) to scroll through the different values, which may be changed
using the UP/DN keys only.
After F3 is pressed, when it is on the last value, the next screen will appear.
Press the middle button (F2) to read the value of the sensor.
Press STOP to discontinue a cycle.
Temp 3 (Option):
Temperature of sensor 1.
Refer to Temp1 for instructions.
Temp 4 (Option):
Temperature of sensor 2.
Refer to Temp1 for instructions.
Temp 5 (Drain)
Temperature of sensor 5
Refer to Temp1 for instructions.
Jkt Pres:
Jacket Pressure.
Refer to Chm Prs for instructions.
Gen Pres:
Generator Pressure.
Refer to Chm Prs for instructions.
D1 Pres:
Pressure in Gasket1.
Refer to Chm Prs for instructions.
The system calibrates the new Offset and Gain and loads them into the non-erasable
memory.
As a result, while running a 134ºC (273 F), program the correction is automatically
made, while at 121ºC (250 F) there is no change.
Sensor no. 1 reads – 60ºC (140°F) and the actual temperature is 65ºC (149°F) (in the
lower range), and in the upper range reads 130ºC (266°F) and the actual temperature is
135ºC (275°F).
Warning!
If maintenance is necessary behind any service access panel(s) while the system is
operating, proceed as follows:
1. Ensure the chamber door(s) are closed.
2. Lock the system by pressing the emergency switch to turn OFF all electrical
power to the autoclave and withdraw the key.
3. Open the service access panel(s) and enter the service area, and take the key
with to prevent accidents and unauthorized use.
4. Disconnect the door opening solenoid(s).
5. Re-insert the key, and turn ON the all electrical power to the autoclave to
operate the system.
6. Carry out the required maintenance.
7. Turn OFF all electrical power to the autoclave once again. See step 2 & 3.
8. Re-connect the door opening solenoid(s).
9. Replace the service access panel(s).
10. Re-insert the key, and turn ON the all electrical power to the autoclave, and
continue working.
Warning!
Before testing the safety valve, wear heat resistant safety gloves and keep all
body parts away from the steam flow.
Attention!
Make sure that the test is performed while the door is closed.
1.2 Set the pressure of the working pressure switch and cut off pressure switch to
6 bar.
1.3 Operate the generator and verify that the pressure increases by checking the
generator pressure gauge.
1.4 Verify that the safety valve blows in the range of 5–5.5 bar. (75 – 80 psi).
1.5 If the safety valve did not blow at the pre-set pressure stop the operation of
the generator, decrease the pressure to atmospheric pressure and replace
the safety valve with a new one.
1.6 If the safety valve was replaced, repeat step 1.1—1.4 to test the new one.
1.7 Re-adjust the pressure of the working pressure switch to 3.5—4 bar, and then
Re-adjust the cut off pressure switch to 5 bar.
1.8 Turn ON the autoclave green toggle switch when the test is done.
2.2 Turn the adjustment knob one turn in the pressure increase direction.
2.3 On the solenoid valve battery, open manually valve 91. This is done by
turning the adjustment screw until the screw's slot is vertical.
2.4 Operate the autoclave and verify that the pressure increases.
2.5 Verify that the safety valve blows in the range of 2.8 –3.0 bar (40 – 44 psi).
2.7 If the safety valve was replaced, repeat step 2.1—2.5 to test the new one.
2.9 Readjust the pressure regulator to the original position. Use the marking as
mentioned above in Step 2.1
Warning!
It is strictly forbidden for any person to enter the service area behind the service
access panels, except the trained technician.
If, for any reason it is necessary to open the service access panel, the person
must shut the system by pressing the emergency switch, withdrawing the key and
keeping the key on him, to prevent accidents and injuries.
The technician must follow the instructions in the SERVICE INSTRUCTIONS,
“Working with power ON in Service Area” Section.
Warning!
Before replacing the gasket, verify that the autoclave is cold; that the power is
turned OFF; and, that there is no pressure in the jacket and in the chamber.
2
Legend
6
MAN205-0195042EN Rev. A Aug. 2011
Page 110 of 137 pages
10. SPARE PARTS LIST
Part No. Description
Note:
R– Recommended spare parts list (to be maintained by the operator)
NOTE:
S- SANITARY VALVE.
Legend:
psia ─ absolute pressure in psi
Psig ─ gauge pressure in psi
kPa ─ absolute pressure in kilo-Pascal
InHg ─ pressure (vacuum) in inch-Mercury
PC – Personal Computer
PCS Target platform – Cat Technologies LTD. controlling system based on PCS card.
PCS communication – exchange data between PCS components via RS232 or RS485,
using PCS data exchange protocol.
Calibration – adjusting analog input presentation value by changing gain and offset
values.
Overview
XPCS is a data exchange program that lets you perform downloading of PCS code;
downloading/uploading analog inputs gain and offset values. The program uses PCS
communication module, to connect between target platform and PC.
XPCS Aim
1. Download PCS code data.
2. Calibration.
Minimum Requirements
3. Pentium processor or equivalent.
4. 32MB of RAM, 32 MB of free hard drive space.
5. CD-ROM drive.
6. Available serial communication port.
7. Windows 9X/NT 4.
Using XPCS
If 'Get and set Gain Offset' are checked, when the program downloads, all gain and
offset values will be stored before PCS code downloading, and restored after
downloading is completed.
If 'Get and Set Parameters' are checked, when the program downloads, all parameters
will be stored before PCS code downloading and restored after downloading is
completed.
Note:
The program stores parameters only in these conditions:
CAT Technologies ADMC Program Installed on PC.
The Downloaded file (DWN) has the same name as one of the ADMC type
files (for example if downloaded file name is: LabTN2.DWN, the ADMC file is
compatible, because ADMC type files: LabTN2.mdb exists).
Note:
Only current selected Program (For example: 1-Instruments) parameters will be
saved and restored.
Note:
Because the PCS target platform parameters saving process are complex,
restoring Parameters task takes long time (few minutes)!
Note:
There is no need to edit options every time that the program starts running. The
program saves the settings by pressing the 'OK' button and starts up with the
last settings.
By pressing the 'Connect' button, the program will try to connect to the remote PCS
Target. Opening connection between remote PCS Target and PC performs the following
tasks:
1. Check if COM Port is available.
2. Detect modem.
3. Dial a phone number.
4. Wait for a connection establishment.
5. Check if remote target platforms are connected.
If one of the tasks fails, the program will abort and the connection process will display
the relevant error message.
If the 'Modem active' option is not selected, by pressing the 'Connect' button, the
program will open the communication port. In this case, communication establishment
tasks will be:
6. Check if COM Port is available.
7. Open COM Port.
Note:
In this case the program is not checking if the target platform is connected.
After a connection is established, the main XPCS window will be displayed.
When program is online, the 'Go offline', 'Calibration' and 'Download' buttons will be
displayed.
The calibration window will try to connect with the PCS Target platform.
The connection tasks are:
8. Check if target is connected. In the status bar "Looking for machine…"
is displayed.
9. Upload all 16 analog inputs Gain and Offset values. In the status bar
Uploading gain & offset…" is displayed.
10. Uploading analog inputs values. In the status bar "Connected" is
displayed. This task is performed periodically every 500 milliseconds.
This allows real time refreshing of the analog inputs values.
Gain text box – use it for manual inserting of the Gain value.
Offset text box – use it for manual inserting of the Offset value.
Min and Max – limits for Gain and Offset values. If the ADMC compatible type file is not
found, Min and Max labels will show "N/A".
Note:
When Min and Max are N/A, you must be very careful, because the Gain and Offset
values are not limited in this case and incorrect Gain or Offset values may be inserted.
Upload button – Press this button to upload Gain and Offset values from the target
platform. All 16 analog inputs gain and offset values will be uploaded.
Close button
Pressing this button will close the 'Calibration' window and display main XPCS window.
Download window
Download button
Press this button to perform the downloading of the selected file. While performing
downloading, the program will display downloading process progress messages. After
the downloading process is complete, the status bar will display "Download Finished".
Download Tasks
1. Check if PCS Target is connected. Status message: "Looking for
machine..." is displayed.
2. If the 'Get and Set Gain & Offset' option in 'Options' window is selected,
the program will upload values of all analog inputs gain and offset. The
message: "Uploading Gain and Offset..." will be displayed on the status
bar.
3. If 'Get and Set Parameters' option in 'Options' window is selected, and
the downloaded file type is ADMC compatible, the program will upload
all parameters of the current selected program (e.g.: 1-instruments).
The message: "Uploading Parameters..." will be displayed on the status
bar.
4. Download file. The program will display the 'Downloading…' dialog
window with progress bar and counter of the downloaded packets:
5. Wait for the target platform startup. After the downloading of the file is
completed, the PCS Target platform restarts. It takes a few seconds
until the target starts running with the new code and before downloading
parameters and gain/offset. The technician must wait until the target will
start again to communicate with the PC. The message: "Waiting for
machine startup..." will be displayed on the status bar.
Note:
If an error occurs during download process, the relevant error message will be
displayed. The message box with the 'Retry' option will be displayed.
After the completion of the downloading process, the Download window will be displayed
as follows:
Note:
Upload and Download green messages of the Parameters and Gain & Offset
tasks are displayed only if the relevant options were selected in the 'Options'
window.
1. Make sure, that the downloading program includes the Modem Auto
answer command determination. (Main>>Startup>>First Row)
Auto Answer
Command
V90/56K MODEM
Comunication Port To the Autoclave Comunication Port
5 5 5
9 9 9
Modem 4 4 4
Telephone Connection 8 8 8
Socket To the phone Line 3 3 3
7 7 7
2 2 2
6 6 6
1 1 1
D-Type-9 Female
9 VDC Inlet D-Type-9 Male D-Type-9 Male
PS
3. Check the Jumpers State according RS232 communication.
CAT Technologies
4. Turn ON the modem. Title
Modem Conection to The Autoclave
5. Turn ON the autoclave. Size Document Number Rev
A 0700002 1