Tuttnauer Valueklave 2540 User manual

TECHNICIAN
MANUAL
Laboratory Vertical Steam Sterilizers
models
2540, 3150, 3170, 3850, 3870, 5050, 5075
ELV Standard Autoclave
ELVC Including Fast Cooling System
ELVPRC Including Preparation for Fast Cooling System
Cat. No. MAN205-0060000EN Rev.AA
Tuttnauer Europe B.V., Hoeksteen 11 4815 PR P.O. Box 7191 4800 GD Breda, The Netherlands
Tel: [phone], Fax: [phone]

Page 1 of 132 Pages
TABLE OF CONTENTS
PARAGRAPH PAGE NO.
1. INTRODUCTION ....................................................................................................4
2. SYMBOL DESCRIPTION......................................................................................4
3. INSTALLATION INSTRUCTIONS.....................................................................5
3.1 Installation Site.................................................................................................6
3.2 Connection of the pressure regulator................................................................6
4. TESTS.......................................................................................................................11
4.1 Installation Tests.............................................................................................11
4.2 Periodical Tests...............................................................................................11
5. WATER QUALITY ................................................................................................12
5.1 Water for Generating Steam ...........................................................................12
5.2 Water for the Vacuum pump and drain cooling..............................................12
5.3 Reverse Osmosis..............................................................................................12
6. DESCRIPTION OF THE CONTROL SYSTEM.............................................13
6.1 Digital Board DIG - T2...................................................................................13
6.2 Analog Board ANL-T2....................................................................................15
6.3 AC - Board - AC-T1........................................................................................16
7. CALIBRATION OF TEMPERATURE AND PRESSURE............................17
7.1 Method of Calibration:....................................................................................17
7.2 Temperature Calibration Procedure...............................................................18
7.3 Pressure Calibration Procedure......................................................................20
8. TEST POINTS ........................................................................................................21
9. SOFTWARE PROGRAMMING PROCEDURES............................................22
9.1 General ...........................................................................................................22
9.2 Changing Cycle Parameters............................................................................22
9.3 Resetting the Autoclave...................................................................................30
9.4 Test Mode........................................................................................................30
10. REPLACING ELEMENTS ..................................................................................31
10.1 Safety Tests after Repair.................................................................................31
10.2 Replacing the Circuit Breaker.........................................................................32
10.3 Replacing the Safety Valve..............................................................................33
10.4 Replacing the Door Gasket .............................................................................34
10.5 Replacing the electronics board (control panel)..............................................35
10.6 Replacing the Electronics Box........................................................................36
10.7 Cut-Out Thermostat........................................................................................39
10.8 Replacing Heating elements............................................................................40
10.9 Safety Door Locking System for models 2540, 3150, 3170, 3850, 3870 ..........41
10.10 Safety Door Locking System for models 5050, 5075 .......................................43
10.11 Disassembling and Assembling the Door Cover, Models 2540, 3150, 3170,
3850, 3870.......................................................................................................44

Page 2 of 132 Pages
TABLE OF CONTENT (Cont.)
PARAGRAPH PAGE NO.
10.12 Disassembling and Assembling the Door Cover, Models 5050, 5075..............46
10.13 Replacing the locking microswitch (Models 5050, 5075)................................49
10.14 Replacing the safety-opening valve (Models 5050, 5075)................................50
10.15 Replacing the “DOOR CLOSED” microswitch (Models 5050, 5075).............51
10.16 Replacing the solenoid lock (Models 5050, 5075)...........................................52
10.17 Cleaning and Replacing the Water Level Electrodes......................................53
10.18 Replacing the Printer......................................................................................54
10.19 Replacing the Door Switch (models 2540, 3150, 3170, 3850, 3870)................56
10.20 Replacing the Locking Device (models 2540, 3150, 3170, 3850, 3870)...........57
10.21 Replacing the Plunger or Coil of the BACCARA Solenoid Valve...................58
11. IN-OUT TEST ........................................................................................................59
12. TROUBLESHOOTING .........................................................................................60
12.1 Displayed Messages and Reference to Trouble Shooting................................60
12.2 Pre-process malfunction .................................................................................61
12.3 In Process Malfunction...................................................................................67
12.4 Mechanical malfunction.................................................................................86
13. LIST OF SPARE PARTS .....................................................................................87
14. PRESSURE VS TEMPERATURE FOR SATURATED STEAM.................97
15. XPCS Manual .......................................................................................................101
16. VALVES NUMBERING .....................................................................................114

Page 3 of 132 Pages
TABLE OF CONTENT (Cont.)
DRAWINGS PAGE NO.
Rear View Model 2540........................................................................................................... 7
Rear View Models 3150, 3170 ............................................................................................... 8
Rear View Models 3850, 3870 ............................................................................................... 9
Rear View Models 5050, 5075 ............................................................................................. 10
Control System Block-Diagram........................................................................................... 13
DIG- T2 Board .................................................................................................................... 14
ANL - T2 Board................................................................................................................... 15
AC-T1 Board ....................................................................................................................... 16
Vessel Assembly Models 2540, 3150, 3170, 3850, 3870....................................................... 92
Vessel Assembly Models 5050, 5075.................................................................................... 93
Door Tightening Bolt – Assembly........................................................................................ 94
Door Locking System........................................................................................................... 95
Water Outlet Strainer .......................................................................................................... 96
Piping Drawing: 2540 ELV &, ELVPRC .......................................................................... 116
Piping Drawing: 2540 ELVC............................................................................................. 117
Piping Drawing: 3150, 3170, 3850, 3870 ELV & ELVPRC .............................................. 118
Piping Drawing: 3150, 3170, 3850, 3870 ELVC................................................................ 119
Piping Drawing: 5050, 5075 ELV & ELVPRC.................................................................. 120
Piping Drawing: 5050, 5075 ELVC................................................................................... 121
Electrical Wiring Diagram For Autoclave Model 2540 ELV ............................................ 122
Electrical Wiring Diagram for Autoclave Models 3150/3170 ELV ................................... 123
Electrical Wiring Diagram for Autoclave Models 3850/3870 ELV 3x400V ...................... 124
Electrical Wiring Diagram for Autoclave Models 3850/3870 ELV 3x230V ...................... 125
Electrical Wiring Diagram for Autoclave Models 3850/3870 ELV 3x208V ...................... 126
Electrical Wiring Diagram for Autoclave Models 5050/5070 ELV 3x400V ...................... 127
Electrical Wiring Diagram for Autoclave Models 5050/5070 ELV 3x230V ...................... 128
Electrical Wiring Diagram for Autoclave Models 5050/5070 ELV 3x208V ...................... 129
Switch Box Wiring Diagram.............................................................................................. 130
Open Switch Box............................................................................................................... 131
Closed Switch Box............................................................................................................. 132

Page 4 of 132 Pages
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.
2. SYMBOL DESCRIPTION
Caution! Consult accompanying documents
Caution! Hot surface.
Caution! Hot steam.
Protective earth (Ground)
Stand by

Page 5 of 132 Pages
3. INSTALLATION INSTRUCTIONS
For all the ELV models, 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:
Model Power
Recommended
Circuit Breaker
2540 1Ph, 230V/50/60Hz 20A
3150/70 1 or 2 Ph, 230V/50/60Hz 25A
3850/70 3 Ph, 208V/50/60Hz 25A
3850/70 3 Ph, 230V/50/60Hz 25A
3850/70 with switching box 1 or 2 Ph, 230V/50/60Hz 30A
3850/70, 5050/75 3 Ph, 400V/50/60Hz 20A
5050/75 3 Ph, 208V/50/60Hz 30A
5050/75 3 Ph, 230V/50/60Hz 30A
5050/75 with switching box 1 or 2 Ph, 230V/50/60Hz 45A
If the autoclave is a 3 phase 3870, 5050 or 5075 autoclave and has to be connected
to a one phase power network, 1 x 230V, 50/60Hz., connected 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 1717:2001 regulations
and local regulations.
.

Page 6 of 132 Pages
FLOW DIRECTION
5
4
3
2
1
6
3.1 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.
5. Leave the space free around the autoclave for maintenance and service
requirements.
3.2 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
2Reducer, Female 3/4" BSP to Male
1/2" BSP, Brass FIT100-0424
3Reducer, 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
5Fitting, 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 7 of 132 Pages
REAR VIEW MODEL 2540

Page 8 of 132 Pages
REAR VIEW MODELS 3150, 3170

Page 9 of 132 Pages
REAR VIEW MODELS 3850, 3870

Page 10 of 132 Pages
REAR VIEW MODELS 5050, 5075

Page 11 of 132 Pages
4. TESTS
4.1 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.
4.2 Periodical Tests
PERIOD TEST
2
months Test the safety valve by operating it
.
6
months
Remove the cover of the autoclave, tighten the screws of the heaters and
the electrical connections at the heaters, valves and connectors in the
control box.
Year
Check the continuity of the grounding connections.
Check the temperature and pressure calibration.
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, heaters and
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!

Page 12 of 132 Pages
5. WATER QUALITY
5.1 Water for Generating Steam
The distilled or mineral – free water supplied to the sterilizer shall be according
to the table below:
Physical Characteristics and Maximum acceptable contaminants levels
in steam for sterilizers
(According to EN 13060:2004).
Element Condensate – allowable content
Silicium oxide. SiO2≤0.1 mg/kg
Iron ≤0.1 mg/kg
Cadmium ≤0.005 mg/kg
Lead ≤ 0.05 mg/kg
Rest of metals except iron,
cadmium, lead ≤0.1 mg/kg
Chloride (Cl) ≤0.1 mg/kg
Phosphate (P2O5)≤0.1 mg/kg
Conductivity (at 20°C) ≤3 μs/cm
pH value (degree of acidity) 5 to 7
Appearance Colourless clean without sediment
Hardness (Σ Ions of alkaline earth) ≤0.02 mmol/l
Compliance with the above data should be tested in accordance with
acknowledged analytical methods, by an authorized laboratory.
Attention:
We recommend testing the water quality once a month. The use of water 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.
5.2 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.
5.3 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 13 of 132 Pages
6. DESCRIPTION OF THE CONTROL SYSTEM.
(See CDR Control diagram).
The control system is based on 3 electronic boards designed according to the autoclave
requirements, the digital board DIG-T2 containing the micro-controller memories,
buffers and digital ICs and the analog board ANL-T2 which performs the processing
of signals coming from the sensors and switches. The AC-T1 board consists of filters
and AC drivers. DC voltages 12V and 5V, supplied by a switching type power supply,
powers the 3 electronic boards.
CONTROL SYSTEM BLOCK-DIAGRAM
The system is provided with communication interfaces RS 232 to PC and to parallel
printer.
6.1 Digital Board DIG - T2
— The digital board is connected to the keypad panel, to the parallel printer
and to the analog board ANL-T2.
— The board contains the micro-controller (U15) type 80C32 that runs the
software program of the system.
— On the board, are three types of memories:
1) EPROM memory (U17), part no. 27512 storing the program codes.
2) RAM memory (U21) with a capacity of 32KB for the temporary data
during the running of the program.
3) EPROM memory (U22) that is a fixed serial memory with an
electrical writing and erasing.
— This EPROM serves as a non-volatile memory, enabling the system to
change follow-up tables during running of program codes, and ensuring
this data is not lost in case of power failure.
— The board contains an optimal Real Time Clock (U12), which serves as a
clock to the system, including a back-up battery, which ensures the clock,
runs continuously even when the autoclave is not powered.
DS 1
BZ1
97-05
C22
2
DIG T3
1
JP1
D1
RP1
U18
U8
C2
C3
C4
8
1 JP3
R4
U3
Q1
R2
U4
U19
U1
R1
20
19
R3
C16
Y1
C15
R9
U14
U11
3 7
1
SKT
U17
U16
U12
C17
U21
C9
C7
C6
C5
U15
+
+
DIG-T2 BOARD
34
33
C24
C23
U22
C25
37
19
20
1
PLUG
JP1
1
JP8
1
JP12
1
JP9
1
JP3
1
JP10
1
JP6
1
JP7
P1
12 1
JP5
JP2
1
JP4

Page 14 of 132 Pages
This component is optimal because it is related to the operation of the
printer, which is also an optional item.
— The board contains a watchdog, which detects any faulty situation in the
running program code. It performs an automatic reset of the micro-
controller and stops all the commands to avoid an uncontrolled activation
of any of the heating elements or the valves.
— The board functions as an MMI (Man-Machine Interface). It is connected
to a LCD display of two rows with 16 characters on each row and to the
following light indicators:
— START (autoclave in process),
— FAIL (the process failed),
— WATER (no water in the reservoir),
— DOOR (the door is not closed).
A keyboard connected to the digital board, serves as a control panel containing
the command and programming keys.
— The digital inputs and outputs are transferred to the system, as follows:
— Through the digital board to the analog board by means of buffers
74HC377.
— RS232 interface is performed on the board by the U13 component, the
signal is transmitted to the communication connector located on the ANL-
T2 board.
— The printer is connected directly to this board, connector DS1 enables to
connect the DPU-20 printer manufactured by SEIKO.
The printer receives the data and the supply voltage directly from this
connector.
The layout of the DIG-T2 board components is provided below
C1
0
DS
1
BZ
1
97-05
C2
2
2
DIG
T
1
.V
3
1
C1
2
JP 1
D
1
RP
1
U1
8
RP
2
U 7
U8
C1
C2
C3
C4
8
1JP3
R4
JP
4
C1
9
U3
Q 1
R1
3
+
R2
U4
U1
9
U1
U2
0
U6
R1
20
19
R8 R7 R6 R5
R3
U1
3
C1
6
Y1
C1
5
R9
U5
U1
4
U1
0
U1
1
37
1
SK
T
U1
7
U1
6
U1
2
C1
7
R1
1
C2
1
U2
1
C9
C8
C7
C6
C5
C1
1
U1
5
+
+
R1
2
C2
0
C1
3
C1
4
34
33
C2
4
C2
3
U2
2
C2
5
U2
3
H2
DIG- T2 BOARD

Page 15 of 132 Pages
6.2 Analog Board ANL-T2
The analog board contains the drivers of the valves, heaters and pump. It
contains the sensors circuits connected to the control system, and serves as a
junction to the autoclave connections.
The input is 12VDC & 5VDC and the output is for all the signals to the
autoclave.
— The power supply provides the DC voltages 12V and 5V through the
connector JP3 to the board and further to the DIG-T2 board.
— The computer is connected to the board through the connector P1, by
RS232 interface.
— The analog and digital inputs, from the temperature sensor, electrode door
switch, etc. are connected through connector JP6, the conversion circuits
of the sensors are located on this board.
— The pressure sensor MPX2200 that measures the chamber pressure is
connected to the board through connector JP8, to the conversion circuit of
the sensor that is located on this board.
— The analog to digital conversion circuit A/D (U5) and the analog
multiplexer (U6) for 8 analog inputs (temperature, pressure, and electrode)
are located on this board and transfer digital signal to the DIG-T2 board.
— All the drivers and power circuits to the solenoids (valves, door locking)
are included on this board.
Layout diagram of the ANL-T2 is provided below.
ANL - T2 BOARD
JP6
12 1 1
1
JP11
1
JP2
37
19
JP7
20
1
JP9
1
PLUG
JP1
JP5
JP3
ANL T1 BOARD
JP4
1
P1
JP10
1
1
JP12 JP8
11

Page 16 of 132 Pages
6.3 AC - Board - AC-T1
This board receives command signals from ANL-T2 board designated to
activate AC devices. It converts them to AC mode.
The AC-T1 board provides AC filtering for the power supply to the control
system and protection from sharp current fluctuations.
The AC-T1 board includes:
— AC drivers for the AC devices (pump, heaters, etc.) up to 6A.
— AC - input connector JP3.
— Filter circuit based on L1C5, the power transfer from the filter to power
supply via JP2.
— Spike protection - RV1÷3.
— Three - 230/115 VAC output channels, triac control circuit.
Q1 - 16Amp - JP4/1,2
Q2 - 8 Amp - JP7/1
Q3 - 8 Amp - JP7/2
AC-T1 BOARD
R8 C2
JP7
R7 C1
1
JP1
R4
R1
R3
U1
ETYPEAC-97
R2
Q1
RV1
R12
R5
C3
Q3
R10
U3
R11
R9
L1
RV3 RV2
JP4 JP3
1
JP5
C5
R6
U2
1
JP6
JP2
Q2
(JP3,JP4,JP7 ON THE BOTTOM SIDE OF THE BOARD)
CAT TECH.

Page 17 of 132 Pages
7. CALIBRATION OF TEMPERATURE AND PRESSURE
7.1 Method of Calibration:
The calibration of temperature and pressure is performed digitally.
The temperature and pressure measuring circuits are designed with components
having 1% accuracy.
The temperature circuit is linear and has an output of 100mV÷2400mV for a
temperature range 20°C÷150°C.
The pressure circuit is also linear and has an output of 100mV÷2400mV for a
pressure range 0÷400 kPa.
The measuring at the A/D is limited for values higher than 2400mV or below
100mV.
It is obvious that although the accuracy of the circuit components is 1%, the
sum deviation may reach 5%. Therefore calibration is necessary.
The system has a non-volatile memory in which the offset and gain data of the
sensors are stored.
Calibration is performed by use of the keyboard (or the communication port for
computer use).
Following is a description of the calibration of temperature and pressure using
the keyboard. The calibration procedure is identical to all autoclave models.
Definition of Gain and Offset:
Every straight line can be defined by the equation ax+b=y. “a” is the deviation
from y=0 and “b” is the slope of the line. In our case a=Gain and b=Offset.
The system is based on calculation of offset and gain of two points as in the
following example
If the actual measured pressures are 100 kPa & 300 kPa and the displayed
pressure are 90 kPa & 310 kPa respectively, the ‘input Vs pressure” graph will
be as follows.
The calibration method enables to input this data into the system in order to
perform automatic correction of OFFSET and GAIN.
It is necessary to define the two points, which have to be input to the system,
prior to performing calibration.
a
X
Y
INPUT FROM SENSOR
PRESURE
V1
310
300
V2
100
90
READ
ACTUAL

Page 18 of 132 Pages
7.2 Temperature Calibration Procedure
— Press the PROGRAM key.
— The system enables to set the system’s date the time.
— This operation is skipped by pressing PROGRAM key six times.
—CODE:  will be displayed.
— Select Technician Code (011) by the UP/DN keys and press the
PROGRAM key.
— Select CALIB CODE: 107 to calibrate the system by means of the UP/DN
keys and press the PROGRAM key again until TEMP CAL: 
will be displayed.
— Set calibration code to TEMP CAL: 1
— Press the PROGRAM key again and do not change the code.
— The following data will be displayed:
UPPER ROW: A 60.0 R 60.0
LOWER ROW: A 130.0 R130.0
Enter the actual data (A) and the displayed data (R) for two known points as in
the following example:
The actual temperatures are 70°C & 120°C and the displayed temperatures are
68°C & 120°C respectively. the
Proceed as follows:
— On the upper row, change A60.0 to A 70.0 by means of UP/DN keys.
— Press the PROGRAM key.
— The cursor on the upper row will move to R60.0, change to
R68.0 by means of UP/DN keys.
— Press the PROGRAM key.
— The cursor moves to the lower row to A 130.0, change it to A 120.0 by
means of UP/DN keys.
— Press the PROGRAM key.
— The cursor on the lower row will move to R130.0, change to R123.0 by
means of keys UP/DN, then press the PROGRAM key
This completes calibration procedure for temperature.