Tuttnauer 3840 ELVG-D User manual

Technician Manual
Electronic Laboratory Autoclaves
Models 3840, 3850, 3870 ELVG-D
ELVG-D: standard autoclave
C: optional system for fast cooling
PV: optional vacuum pump
BH: optional bio hazard filtration
F: optional fan for super-fast cooling
The Netherlands Tel: [phone], Fax: [phone]
Cat. No. MAN205-0491000EN Rev. F
Tuttnauer Europe B.V.,
Hoeksteen 11 4815 PR P.O. Box 7191 4800 GD Breda,

http://www.tuttnauerusa.com/

Page 1
Table of Contents
Paragraph , page no.
1. Introduction 4
2. Installation Instructions 6
2.1 Installation Site 7
2.2 Connection of the pressure regulator 7
2.3 Front View 9
2.4 Front View for the Fan Configuration 10
2.5 Rear View 11
3. Tests 12
3.1 Installation Tests 12
3.2 Periodical Tests 12
4. Technical Data 14
4.1 Directives and Standards 14
4.2 Water Quality 14
4.3 Reverse Osmosis 15
4.4 Electrical data 16
4.5 Specifications 17
4.6 Overall Dimensions 18
4.7 Construction 18
4.8 Utilities 19
4.9 Symbol Description 20
5. Description of the Control System. 21
5.1 Hardware Control System Components: Block Diagram ................... 21
5.2 Application System Architecture 21
5.3 Interfaces to Users 22
5.4 Inputs and Outputs 22
5.5 Hardware Control System components 24
6. Checking and Changing Parameters and Other Data 28
6.1 Browsing through the menus 28
6.2 Changing a Parameter 29
6.3 Quick options screen 31
6.4 Logging in and entering the Main menu 37
6.5 Directories and subdirectories 38
6.6 System Parameters 41
6.7 Inputs/Outputs 43
6.8 Maintenance 49
6.9 Advanced Options 53
6.10 Version handling 59

Page 2
6.11 Cycle parameters 61
6.12 Temperature sensors 63
6.13 Displayed inputs 64
6.14 Purge (generator models only) 65
6.15 Create Pulse 65
6.16 Keep Heat 67
6.17 Heating 68
6.18 Sterilization 68
6.19 Cooling (“C” models only) 69
6.20 Exhaust 70
6.21 Drying 70
6.22 Ending 72
6.23 Global (for some models only) 72
7. Generator description 75
7.1 Generator Electrical Safety System 76
7.2 The Water Pump for the Steam Generator 77
7.3 GICAR Water Level Controller 77
8. Maintenance and Replacement Procedures: the Autoclave 79
8.1 Preliminary Operations for Each Technician Call 79
8.2 Replacing the Circuit Breaker 80
8.3 Replacing the Safety Valve 81
8.4 Replacing the door gasket 83
8.5 Replacing the door cover 84
8.6 Replacing the Printer 89
8.7 Replacing the Door Micro-Switch 1 91
8.8 Replacing the Door Micro-Switch 2 91
8.9 Replacing the air filter 92
8.10 Replacing the locking motor 93
8.11 Replacing the Plunger or Coil of the 1/4" Solenoid Valve
9
5
8.12 Replacing the Plunger or Coil of the BACCARA Solenoid Valve 96
8.13 Replacing the Mechanic Pressostat 96
8.14 Replacing the Pressostat 0.2 (NC) 97
8.15 Replacing the power supplies, water level board and relays
98
9. Maintenance and Replacement Procedures: the Generator 103
9.1 Access to Generator 103
9.2 Draining the generator 103
9.3 Cleaning and Replacing the Water Level Electrodes 104
9.4 Replacing the Heating Elements 106

Page 3
9.5 Replacing the Generator Side Gauge Glass Indicator Tube 106
9.6 Replacing the Generator Thermostat 108
9.7 The Water Pump Replacement 110
9.8 Releasing the Vacuum Pump Rotor 110
10. Troubleshooting 112
10.1 Autoclave Troubleshooting 112
10.2 Steam Generator Troubleshooting 117
11. List of Spare Parts 120
11.1 Water Outlet Strainer 128
12. Pressure vs Temperature for Saturated Steam 129
13. Valves Numbering 138
14. Drawings 140
14.1 Piping Drawing – Model 3840/3850/70 ELVCG-D 140
14.2 Piping Drawing – Model 3840/3850/70 ELVCPVG-D 141
14.3 Piping Drawing – Model 3840/3850/70 ELVCPVGBH-D
1
42
14.4 Electrical Drawing for The Autoclave 3840-50/3870
ELV(C)(PV)G 380V.......................................................................... 143
14.5 Electrical Wiring Diagram: The Generator 151
14.6 Generator Control Electrical Cascade Diagram 152

Page 4
1. Introduction
This manual, together with the operator’s manual, forms the complete
edition of the Operation and Maintenance instructions. This manual is
intended for the use of the technician. It is forbidden for unqualified and
unauthorized personnel to service the autoclave in accordance with the
instructions in this manual. Any unauthorized service may result in the
invalidation of the manufacturer’s guarantee.
The qualified technician shall be an authorized electrician with the right
qualifications in electronics and shall be familiar with the local
technical/electrical regulations.
Available optional configurations
Models of 3870 ELVG-D model range are laboratory sterilizers
designed especially for the sterilization of instruments, liquids, and
other materials in hospital laboratories, medical laboratories, research
institutes, food laboratories and pharmaceutical facilities.
C
A special feature of the ELVCG-D models is the fast cooling stage for
liquids. In this stage pressure in the chamber is increased by means of
compressed air to compensate the fast decreasing of pressure due to
the fast cooling. The fast cooling shortens the time required for safe
handling of bottles.
Note: there is no cooling option for WR configuration
PV
Special feature of ELVCPV-D models is the vacuum pump that enables
air removal prior to sterilization and during the drying stage.
The advantages of the pre-vacuum sterilizer in comparison to the
regular gravity displacement steam sterilizer are as follows:
— Removal of air pockets from packs and porous loads and most kinds of
tubes (rubber, plastic etc.) by vacuum at the first stage of the cycle.
— Better steam penetration into the load; resulting in effective sterilization.
— Better temperature uniformity.
— Better drying of materials with closed doors due to the vacuum
achieved in the chamber at the end of the sterilization cycle.

Page 5
A special feature of the autoclave is the fast cooling stage for liquids. In
this stage pressure in the chamber is increased by means of
compressed air to compensate the fast decreasing of pressure due to
the fast cooling. The fast cooling shortens the time required for safe
handling of bottles
There is a configuration equipped with fan that allows to shorten the
cooling operation.
BH
In ELVCPVBH-D (bio-hazard) models, a bio-hazard filter installed in the
chamber enables sterilizing bio-hazard load without contaminating the
surrounding.

Page 6
2. Installation Instructions
The following utilities have to be connected (Refer to the drawing below
‘Rear View’ of the autoclave).
Power outlet, as detailed in the table below:
Power
3 Ph, 400V/50/60Hz
Recommended Circuit Breaker
20A
If the 3 phase autoclave has to be connected to a one phase power
network, 1 x 230V, 50/60Hz., connect the 1ph 230V power source to
the supplied switch box that has a 1 phase input (from the power
source) and a 3 phase output (to the autoclave). See details at the end
of this manual.
The power network must be protected by a current leakage relay.
Mineral-free water having a conductibility lower than 15µs
(microsiemens), through a 1/2” flexible hose.
To obtain water quality meeting requirements a deionization
column or reverse osmosis apparatus can be installed. The water must
be delivered at a pressure of 2-3bar. A pressure reducer shall be
installed at the water source outlet as instructed below.
For fast cooling (if this option is provided):
Feed water from the water network, pressure 2-3bars, connected
through a 1/2” pipe. A pressure reducer shall be installed at the water
source outlet as instructed below.
Compressed air, from a mobile compressor or compressed air network
at pressure 3-4 bars, will be set at 1.6-2bars at the autoclave inlet is to
be connected by a flexible conduit of 3/16”.
The air must be of instrumental quality filtered at 5µ and free of
humidity and oil drops.
Drain connected by 1/2” pipe, located at the rear of the unit. The
chamber exhaust and coolant water is evacuated to an open waste
funnel. The drainage piping must be heat resistant, to 80ºC, non-
continuous flow.
Attention:
Connection of water system to the autoclave must be performed
through "BACK FLOW PREVENTION SYSTEM" installation as per
EN 1717.

Page 7
2.1 Installation Site
1. Install the autoclave according to the following guidelines:
2. Place the autoclave on the floor. Verify that the surface is leveled.
3. All utility supplies must be prepared in accordance with requirements,
before autoclave installation e.g. mineral-free and tap water,
compressed air, one or three-phase power network, connection to the
drain of the building.
4. Leave the space free around the autoclave for maintenance and
service requirements.
2.2 Connection of the pressure regulator
This paragraph refers to the pressure regulator of the feed water and to
the pressure regulator of the mineral free water.
1. Attach the pressure regulator to the facility's water outlet.
2. Connect the supplied flexible hose to the pressure regulator's assembly
outlet and to the autoclave's water inlet.
3. Verify that the pressure regulator is in right direction. The flow direction
is indicated by an arrow stamped on the pressure regulator.
4. Verify that water flows freely in the feed water and in the mineral free
water lines.
No.
Description
Cat No.
1
Side of water supply source
N/A
2
Reducer, Female 3/4" BSP to Male 1/2" BSP, Brass
FIT100-0424
3
Reducer, Female 1/2" BSP to Male 1/4" BSP, Brass
FIT100-0425
4
Pressure Regulator, Water, In-Line, with Strainer, 1/4
x 1.5 bar
GAU029-0059
5
Fitting, Adaptor, M 1/2" BSP x M 1/4" BSP, Brass Ni
plated
PNE100-0042
6
Side of flexible hose (to autoclave
N/A

Page 8
FLOW DIRECTION
5
4
3
2
1
6

Page 9
2.3 Front View
No.
Description
No.
Description
1
Front leg
8
Display
2
Rear leg
9
Keyboard
3
Left service door
10
Printer cover
4
Left service door grip
11
Paper slot and paper cutter
5
Left service door lock
12
USB socket
6
Door cover
13
Main switch
7
Pressure gauge
14
Printer
9
10
5
6
7
8
11
14
4
3
2
1
12
13

Page 10
2.4 Front View for the Fan Configuration
There is a configuration equipped with a fan that allows shortening the cooling
operation. The fan is located on the door of the autoclave.
Fan

Page 11
2.5 Rear View
No.
Description
No.
Description
1
fan grill
9
air pressure regulator
2
RJ45 connector
10
generator drain outlet
3
circuit breaker
11
tap water inlet
4
electrical socket
12
mineral free water inlet
5
gravitation valve for vacuum pump
13
generator pressure gauge
6
compressed air inlet
14
side gage glass indicator tube
7
autoclave air pressure gauge
15
generator safety relief valve
8
autoclave drain outlet
16
chamber safety relief valve
6
7
9
1
2
3
5
14
13
12
15
8
11
10
4
16

Page 12
3. Tests
3.1 Installation Tests
The service technician shall perform the following preliminary
checks before operating the autoclave:
a. Integrity Check
Perform a visual check to verify that there are no dents, scratches,
broken gauges, etc.
b Leveling Check
Check that the autoclave is leveled.
c. Leakage current test
Check the precise operation of the earth leakage relay.
d. Continuity Check
Check the continuity of the grounding connection.
At this stage operate the autoclave and continue with the tests:
e. Safety Check
Check the safety elements; safety valve and the door locking
mechanisms.
f. Programs Check
Run basic programs of the autoclave and check the operation
sequences, the sterilization parameters etc.
g. Validation
Validate the sterilization cycles, taking in consideration the interface of
packaging/goods/autoclave.
After the above steps are performed, the autoclave is ready for
operation.
3.2 Periodical Tests
Period
Test
2 months
Test the safety valve by operating it.
6 months
Remove the cover of the autoclave, tighten the, valves and
connectors in the control box.
Year
Check the continuity of the grounding connections.
Check the temperature and pressure calibration.

Page 13
Perform validation of the autoclave.
Check the precise operation of the earth leakage relay.
Check that the autoclave is leveled.
Check the safety elements; safety valve, safety and cut-off
thermostats door locking mechanisms.
Run basic programs of the autoclave and check the operation
sequences, the sterilization parameters etc.
Check the water reservoir, piping, plastic parts and electric
wires.
Check and tighten the piping joints to avoid leakage.
Check and tighten all screw connections in the control box,
valves and instrumentation.
Observe the closing device for excessive wear
5 years
Observe the closing device for excessive wear
Safety tests (pressure vessel, efficiency, electrical) shall be performed in
accordance with local rules or regulations, by an authorized inspector.
Only an authorized technician shall perform the 6-months and yearly tests!
Check connections to distilled or mineral free water. Open the
distilled or mineral free water valves. Manually test the distilled or
mineral free water valves by over-riding the appropriate solenoid
valves. If there are no leaks, –leave the water manual inlet taps
open.
Observe the gauge and see that the generator reaches working
pressure.
Check that the jacket pressure gauge, reaches 2.4 bars (35 psi).

Page 14
4. Technical Data
4.1 Directives and Standards
Tuttnauer. Ltd. company meets the provisions of the following standards:
ISO 9001:2008 (Quality Systems)
Tuttnauer. Ltd. company also works in conjunction with and refers to:
ANSI/AAMI ST55 American Society of Mechanical Engineers
Section VIII, Division 1, for unfired pressure vessels.
EN 13060 Small Steam Sterilizers.
UL UL 61010-1
PED 97/23EEC
IEC IEC 61010-2-040 Safety
ISO 17665-1:2006 (Validation and Routine Control)
4.2 Water Quality
The distilled or mineral-free water supply shall be according to the table
below:
Physical Characteristics and Maximum acceptable contaminants
levels in water or steam, for steam generator and sterilizers
(According to EN 285: 2006)
Contaminants in
water supplied to
generator
Contaminants in
condensate at 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, lead
≤ 0.1 mg/l
≤ 0.1 mg/l
Chloride (Cl)
≤ 2 mg/l
≤ 0.1 mg/l

Page 15
Phosphate (P2O5)
≤ 0.5 mg/l
≤ 0.1 mg/l
Conductivity (at
25°C)
≤5 µs/cm
≤ 3 µs/cm
pH value (degree of
acidity)
5 to 7.5
5 to 7
Hardness (Σ ions of
alkaline earth)
≤ 0.02 mmol/l
≤ 0.02 mmol/l
Appearance
Colorless, clean, without sediments
[Minimum specific resistivity of 1 megohm per cm (1 MΩ/cm)]
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.
Use Only deionized water, Having a maximum conductance of 1
microSiemen per cm (1 μS/cm) Tap Water supply
Maximum hardness value 0.7-2.0 mmol/l
The use of soft water is strictly forbidden!
Please consult a water specialist!
4.2.1 Water for the Vacuum pump and drain cooling
The feed water supplied to the liquid ring vacuum pump must meet the
following requirements:
Hardness: 0.7 - 0.2 mmol/l.
Water temperature: shall not exceed 15°C.
Note: The use of heavy scaled water for the vacuum pump cooling, can
cause blocking of the rotor and put the pump out of operation. This
invalidates the guarantee for the vacuum pump.
4.3 Reverse Osmosis
A Reverse Osmosis system may be used to improve the quality of the
water used to generate steam in the autoclave chamber. The use of
mineral free will contribute to better performance and longer life of the
autoclave.

Page 16
4.4 Electrical data
230V configuration
Property
Value:
3840
Value:
3850
Value:
3870
Total Power
9000
9000
9000
Voltage
1Ph,
230VAC
1Ph,
230VAC
1Ph,
230VAC
Amperage
22A w/o
PV, 25A
with PV
22A w/o
PV, 25A
with PV
22A w/o
PV, 25A
with PV
Protection against electrical
shock
Class I (IEC 60601-1)
Mains supply fluctuation
+/- 10%
Degree of protection by
enclosure
IP31
400V configuration
Property
Value:
3840
Value:
3850
Value:
3870
Total Power
9000
9000
9000
Voltage
3Ph,
400VAC
3Ph,
400VAC
3Ph,
400VAC
Amperage
13A w/o
PV, 16A
with PV
13A w/o
PV, 16A
with PV
13A w/o
PV, 16A
with PV
Protection against electrical
shock
Class I (IEC 60601-1)
Mains supply fluctuation
+/- 10%
Degree of protection by
enclosure
IP31

Page 17
4.5 Specifications
Properties
Model
3840
3850
3870
Chamber diameter
380
380
380
Chamber depth
400
500
690
Chamber volume
52 liters.
65 liters.
85 liters.
Overall dimensions
Height
1000
1000
1000
Width
730
730
730
Length
700
700
700
Maximum
dimensions
(door open)
Width
800
800
800
Length
1500
1500
1500
Net weight (kg)
105kg
108kg
113kg
Shipping volume
0.9 m3
0.9 m3
0.9 m3
Shipping weight
133kg
136kg
141kg
Max. Allowable Working
pressure (MAWP)
2.8 bar (40 psi)

Page 18
4.6 Overall Dimensions
4.7 Construction
Chamber and door
material
Stainless steel
Outer Cabinet
Stainless Steel
Chamber insulation
Fiberglass with reinforced
material