Tuttnauer 6690 STS-1V Manual

OPERATION
&
MAINTENANCE
MANUAL
Prevacuum Steam Heated Autoclave
with Steam to Steam Generator
and Vertical Sliding Door
model 6690 STS-1V
S/N: 2301006, 2301007, 2301011, 2301012, 2301013,
2301014, 2301015, 2301016, 2301017, 2301018
Cat.No.: MAN205-0211-002 Rev: C
Manufactured by: Tuttnauer Co. Ltd., P.O.Box 35292, Jerusalem, Israel Tel: [phone], Fax: [phone]

Table of Contents
Incoming Inspection ---------------------------------------------------------------- 1
1. General Information
1.1 Introduction ---------------------------------------------------------------------- 2-3
1.2 Standards --------------------------------------------------------------------------- 3
1.3 Specifications ----------------------------------------------------------------------- 4
1.4 Steam Data-------------------------------------------------------------------------- 4
2. Functional Description
2.1 The Steam to Steam Generator ----------------------------------------------- 5
2.2 The Water Pump------------------------------------------------------------------- 5
2.3 The Piping System ------------------------------------------------------------- 6-7
2.4 The Pneumatic Control System -------------------------------------------- 8-9
2.5 The Water Quality ---------------------------------------------------------- 10-11
2.6 The Electric System ------------------------------------------------------------ 12
2.7 Control System -------------------------------------------------------------- 13-15
3. Sterilization Programs --------------------------------------------------- 16-39
4. Control and Monitoring
♦ Control Panel 'CAT 2007' --------------------------------------------------------40
4.1 Description of panel 'CAT 2007'---------------------------------------------- 41
4.1.1 Keypad ----------------------------------------------------------------- 41-42
4.1.2 Display ----------------------------------------------------------------- 43-44
4.2 Description of Displayed Messages and Safety Measures ------- 45-46
4.3 Operating the Control Panel
4.3.1 Starting up the system ------------------------------------------------- 47
4.3.2 Selecting a Cycle ---------------------------------------------------- 48-50
4.3.3 System Setup -------------------------------------------------------- 51-53
4.3.4 Changing cycle parameters -------------------------------------- 54-58
4.3.5 Test Programs ------------------------------------------------------- 59-60
4.3.6 Display function ---------------------------------------------------------- 61
4.3.7 Display during a cycle ---------------------------------------------- 62-63
5. Calibration ------------------------------------------------------------------------- 64
5.1 Calibrating temperature and pressure ------------------------------------- 65

Table of Contents
5.1.1 Temp 1 --------------------------------------------------------------------- 65
5.1.2 Temp 2 --------------------------------------------------------------------- 66
5.1.3 Temp 3 --------------------------------------------------------------------- 66
5.1.4 Temp 4 --------------------------------------------------------------------- 66
5.1.5 Chamber Pres ------------------------------------------------------------ 66
5.1.6 Jacket Pres ---------------------------------------------------------------- 66
5.1.7 Gen Pres ------------------------------------------------------------------- 66
5.1.8 D1 Pres----------------------------------------------------------------- 66-67
6. Transportation of the Autoclave -------------------------------------------- 68
7. Preparation before Sterilization----------------------------------------- 69-70
♦ Loading and Unloading ---------------------------------------------------------70
8. Installation Instructions --------------------------------------------------- 71-72
9. Operating Instructions -------------------------------------------------------- 73
♦ Control Panel -----------------------------------------------------------------------74
10. Printer
10.1 Printer Operation ---------------------------------------------------------- 75-76
10.2 Printer Handling --------------------------------------------------------------- 77
11. Maintenance of the Autoclave
11.1 Preventive and Periodical Maintenance --------------------------------- 78
SERVICE INSTRUCTIONS
11.2 Safety Tests after Repair----------------------------------------------------- 80
11.3 Troubleshooting ------------------------------------------------------------ 81-85
11.4 Troubleshooting for the Water Pump ‘SHURFLO’ --------------------- 86
11.5 Pressure Switch --------------------------------------------------------------- 87
11.6 Absolute Pressure Transducer --------------------------------------------- 88
11.7 Cleaning and replacing the Water Level Electrodes ------------------ 89
11.8 The GEN - PROTEC electronic board ------------------------------------ 90
11.9 Water Pump Rear Endbell Replacement Kit ------------------------ 91-92
11. 10 Door Oil Piston --------------------------------------------------------------- 93
11.10 Dismantling the Cabinets side panels ---------------------------------- 94

Table of Contents
12. Spare Parts ------------------------------------------------------------------ 95-96
13. Valves Numbering -------------------------------------------------------- 97-98
14. Pressure and Temperature Table for Saturated Steam------------ 99
Drawings
♦ The Pneumatic Control System Drawing ------------------------------------- 9
♦ Vertical Sliding Door------------------------------------------------------------- 100
♦ Vertical Door- Locking Mechanism ------------------------------------------ 101
♦ Piping drawing ------------------------------------------------------------------- 102
♦ Electric drawing for the Autoclave ------------------------------------------- 103
XPCS Manual ------------------------------------------------------------------104-117
♦ Steps for modem connection-------------------------------------------------- 117

Page 1 of 117 pages
INCOMING INSPECTION
The instruments (products) should be unpacked and inspected for mechanical
damage upon receipt. Observe packing method and retain packing materials until the
unit has been inspected.
Mechanical inspection involved checking for signs of physical damage such as:
scratched panel surfaces, broken knobs, etc.
If damage is apparent, file a claim with the carrier. The manufacturer is responsible
for products shipped F.O.B. These products are carefully inspected prior to shipment
and all reasonable precautions are taken in preparing them for shipment to assure
safe arrival at their destination.
WARRANTY
We certify that this instrument is guaranteed to be free from defects in material and
workmanship for one year against faulty components and assembly with the
exception of glassware, lamps and heaters.
The warranty does not include and does not replace routine treatment and preventive
maintenance to be performed according to instructions in paragraph 11.1 'Preventive
and Periodical Maintenance'.
Our obligation is limited to replacing the instrument or parts, after our examination, if
within one year after the date of shipment they prove to be defective. This warranty
does not apply to any instrument, which has been subjected to misuse, neglect,
accident or improper installation or application, nor shall it extend to products, which
have been repaired or altered outside the factory without prior authorization from us.
The Autoclave should not be used in a manner not described in this manual!
Note
If there is any difficulty with this instrument, and the solution is not covered in this
manual, contact our representative or us first.
Do not attempt to service this instrument yourself.
Stipulate the model and serial number and describe the difficulty as clearly as
possible so we may be able to diagnose the problem and hence provide a prompt
solution.
For technical information or service please contact our representative at:
Tuttnauer USA Co.
25 Power Drive Hauppauge
NY, 11788, USA
Tel:[phone]
¬Fax:[phone]
Email: [email protected]
Our web site: www.tuttnauer.com

Page 2 of 117 pages
1. GENERAL INFORMATION
1.1 Introduction
This autoclave is a pre-vacuum sterilizer designed to cover a large field of applications
for hospitals and medical centers as well as pharmaceutical and biotechnological
industries.
The autoclave operates with saturated steam as the sterilizing agent, and has a
temperature of up to 279ºF and pressure up to 40 psi.
The autoclave is constructed of stainless steel, having a double - walled structure
and is equipped with a steam to steam generator, which supplies clean steam to the
chamber for the sterilization process. There are separate steam lines from the steam
to steam generator to the chamber and from the building steam supply to the jacket.
The autoclave is equipped with one vertical sliding door operated by a hydraulic
system, through two oil cylinders mounted laterally on both sides of the door. The
command pressure of compressed air is transmitted to the oil in the cylinders and
converted into hydraulic pressure, which pushes the pistons up or down, for closing
or opening the door.
The sealing of the chamber is achieved through a heat resistant silicone gasket,
located in a groove on the front side of the autoclave. The gasket is pushed against
the door by steam pressure introduced in the groove, behind the gasket.
Twelve sterilization programs are available, four are intended for unwrapped
instruments (gravity), four for wrapped instruments and packages and four for liquids.
Two test programs are also available, the VACUUM TEST for checking the tightness
of the chamber and piping system and the BOWIE DICK test enabling to check the
efficiency of the sterilization process.
The control system of the sterilizer is based on " State-of -the -Art" microcomputer
technology, ensuring a highly reliable and safe operation. The computerized control unit
ensures a fully automatic operation through the entire cycle, hence after setting the
pre-selected data and starting the operation, no further intervention is necessary.
The selected program, the main phases of the cycle and the status of the machine are
controlled and displayed on digital readouts. For process documentation, the important
information concerning operation is printed in hard copy.
For optimal control accuracy of the sterilization parameters, the system is equipped with
three temperature sensors, three pressure transducers and a pressure switch having
the following functions:
♦ The temperature sensors: 2 measuring the condense temperature (control and printout)
and the drain control output.
♦ The pressure transducers: the chamber pressure (control and monitoring), the jacket
pressure (control) and gasket pressure.
♦ The pressure switch regulates the steam pressure output of the steam generator.
Four pressure gauges measure the gasket, jacket, chamber and steam generator
pressure.
A programming mode, which can be entered by an access code, enables the technician
to set a number of additional parameters and operation modes.

Page 3 of 117 pages
The keyboard located on the front panel enables the operator to start and stop the
cycle.
Only the responsible person has access to select the program and change the
major parameters by using the key.
Optionally, a personal computer can be connected to the control system, through the
interface board RS232, which can be, operated 8 meters away from the autoclave.
The PC, operating under WINDOWS displays the status, data and processing in real
time in graphic and digital form at the same time recording and logging the data.
The communication PC-control unit enables the complete control of the autoclave
through the PC, including program selection, starting and stopping the cycle, setting
of parameters and the real time clock (data and time of the day).
1.2 Standards
This autoclave meets applicable requirements of the following standards:
1. A.S.M.E. Code, Section VIII Division 1 for unfired pressure vessels.
2. HTM 2010 – Sterilization and HTM 2031 - Clean Steam for Sterilization.
3. Complies with AAMI/ANSE ST8- Hospital Steam Sterilizers.
4. Complies with Underwriters Laboratories (U.L 2601-1) requirements
Tuttnauer is approved for ISO 9002 (Quality Systems), EN 46002 (Quality
Systems for Medical Devices) and ISO 13488 (Quality systems for Medical
devices – Particular requirements for the application of ISO 9002).
.

Page 4 of 117 pages
1.3 Specifications
Product data Model 6690 – 1V
W26’’ (660 mm.)
H26’’ (660 mm.)
Chamber Dim.
D36’’ (1070 mm.)
Chamber volume 467 l.
W1215 mm.
H1990 mm.External dim.
D1450 mm.
Net Weight 1150 kg (2540 lb)
Degree of protection IPX 4
Utilities
Steam supply
1’’, 50-80 PSI,
160 Lbs/Hr Peak
88 Lbs/Hr Av
g
.
Cold water supply
Maximum hardness value 72-215 TDS of CaCO3
Recommended tem
p
erature 59°F
¾’’, 50-80 PSI,
12.5 GPM Peak
275 GPH Avg.
Compressed air requirements Pressure 90-110 PSI, 3.5 SCFM
3/8" thread connection.
Electrical data:
Voltage 1 ph, 115V/60Hz
Utility 10 A
Current Consumption 6A
1.4 Steam Data
Working pressure 4 Bar (59 psi)
Test pressure 15.5 Bar (228 psi)
Safety relief valve 5 Bar (75 psi)
Plant Steam (Input) Generated Steam (Output)
pressure
(bar)
Temp.
(°C)
Rate
Kg/h
pressure
(bar)
Temp.
(°C)
Rate
Kg/h
8 176 137 2.6 140 116
7 171 88 2.6 140 80
6 165 52 2.6 140 47
5 159 24 2.6 140 22

Page 5 of 117 pages
2. FUNCTIONAL DESCRIPTION
2.1 The Steam to Steam Generator
The steam for the sterilization process is supplied from the building main steam
supply to a built in steam to steam generator, which produces clean steam and is
directly connected to the autoclave chamber.
Water to the steam generator is supplied by a single-phase pump, from a water
reservoir, which is connected to a source of distilled or mineral free water.
A water level control system, consisting of two electrodes mounted on top of the
boiler and connected to the electronic control board maintains through the pump
and a solenoid valve, a constant water level and ensures a safe operation of the
steam to steam generator.
A pressure switch connected through the electronic board regulates the output
steam pressure. A safety relief valve blows off at a pressure of 40 psi, to prevent
build-up of overpressure in case of control failure.
Only mineral - free water or distilled water will be used for operation of the
generator. See also par. 2.5 ‘Water Quality’.
2.2 Water Pump for the Steam Generator
The suction of the pump is connected to the water reservoir filled with mineral-free
water and mounted on the side of the autoclave. The mineral water is heated to
80ºC and maintained at this temperature so that the steam obtained from this
water has a low content of non-condensable gases. A PT100 temperature sensor
controls the water temperature.
A float valve keeps a constant level of water and prevents an overflow of water out
of the reservoir.
A lower float switch stops the operation of pump and heaters, when the water level
drops below this switch.
The Vacuum Breaker
When the generator cools down, it generates vacuum inside.
The vacuum breaker breaks it so that the generator won’t draw water from the
mineral free water reservoir.