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Related Manuals for Tuttnauer 2540 EHS
Summary of Contents for Tuttnauer 2540 EHS
- Page 1 TECHNICIAN MANUAL Electronic Table - top Pre and Post Vacuum Autoclaves models 2540 & 3870 EHS MAN205-0063-005E Rev. D Cat. No.
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Page 2: Table Of Contents
TABLE OF CONTENTS PARAGRAPH PAGE NO. INTRODUCTION....................4 SYMBOL DESCRIPTION ..................4 INSTALLATION INSTRUCTIONS ..............5 ........Site requirements for installation of a 2540 EHS ........Site requirements for installation of a 3870 EHS ..............Suggested Site Drain Drawing ................Electrical Specifications ................... - Page 3 TABLE OF CONTENT (Cont.) PARAGRAPH PAGE NO............... Replacing the DIG-T2 board ..................Drain Valve Repair ..............Replacing the Pressure Gauge ......Replacing the Door Bellows (Located in the door bridge) ................. Replacing the Printer ................. Replacing the Door Switch ..............
- Page 4 ......................... TRAY ................TRAY HANDLE (CMT240-0001) ............DOOR TIGHTENING BOLT – ASSEMBLY ............... PIPING DRAWING FOR 2540 EHS ............... PIPING DRAWING FOR 3870 EHS ............ELECTRICAL DRAWING FOR 2540 EHS ......ELECTRICAL DRAWING FOR 3870 EHS (TILL S/N 2307039) ......
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Page 5: Introduction
Operation and Maintenance instructions for the EHS pre and post vacuum autoclave. This manual is intended for the use of the technician. It is strongly recommended that only qualified and Tuttnauer factory trained personnel service this autoclave and do so in accordance with the instructions in this manual. -
Page 6: Installation Instructions
INSTALLATION INSTRUCTIONS For proper operation, these are the required utilities that need to be supplied for each model EHS: Site requirements for installation of a 2540 EHS Caution The sterilizer must be placed on a rigid and leveled surface and must be able to hold the weight of the device and loaded material. -
Page 7: Site Requirements For Installation Of A 3870 Ehs
Site requirements for installation of a 3870 EHS Caution The sterilizer must be placed on a rigid and leveled surface and must be able to hold the weight of the device and loaded material. 1. Counter top able to support a minimum 400 lb. (the unit is shipped with a suitable stand - 26”W x 33”D x 34”H) 2. -
Page 8: Suggested Site Drain Drawing
Suggested Site Drain Drawing Discharge hoses from EHS Hanger with 4” x 4” PVC air break 90º bend Milford Type Copper Coated Hanger 1 ½” PVC To trap 4” Metal worm gear clamp Caution! Wastewater should be brought into the public sewage network in accordance with the local rules or requirement i.e. -
Page 9: Electrical Specifications
Electrical Specifications Value Property 2540 3870 Heaters Power 3000W 6000W Total Power 3200W 6200W Voltage (V) 1 ph / 208 3 ph / 208 Amperage (A) Frequency (Hz) 50/60 50/60 Protection against electrical shock Class I (IEC 60601-1) Note: In order to avoid any injury by electrical hazard, it is recommended that a ground fault protection device be installed in the electrical panel feeding the autoclave (local codes may make this mandatory). -
Page 10: Rear View
REAR VIEW... -
Page 11: Installation Tests
Installation Tests At the time of installation, before the autoclave can be okayed for daily operation the service technician needs to perform the following preliminary checks: ♦ Integrity check: perform a visual check to verify that there are no dents, scratches or broken components on the autoclave ♦... -
Page 12: Water Quality
Water Quality 3.8.1 Built-in Steam Generator The distilled or mineral – free water supplied to the steam generator shall be according to the table below: A Reverse Osmosis system meeting the qualifications below may be used to provide water for the steam generator. The better the quality of the water, the better performance, the less maintenance and the longer the life of the autoclave. -
Page 13: Description Of The Control System
DESCRIPTION OF THE CONTROL SYSTEM. System Summary The hardware portion of the control system consists of a keyboard and 3 additional electronic boards designed specifically to match the requirements of the EHS autoclave. The main board is the digital board, DIG-T2, which contains the microprocessor and is responsible for controlling the system. -
Page 14: Keyboard
Keyboard The keyboard is mounted to and directly connected to the DIG-T2 board and functions as an MMI (Man-Machine Interface). The keypad serves as a control panel containing the command and programming keys. It also includes an LCD display with two rows of 16 characters for cycle progress updates and error messages. -
Page 15: Dig- T2 Board
3) FLASH memory (U17) 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 a Real Time Clock element (U12), which serves as a clock to the system. -
Page 16: Analog Board Anl-T2
Analog Board ANL-T2 The analog board contains the DC power transistors that drive the valves, heaters and pumps. It contains the sensor circuits that decode the information from the temperature and pressure sensors before passing that information on to the DIG-T2 board. All the systems electronic components are connected through the ANL-T2 board. -
Page 17: Anl- T2 Board
Layout diagram of the ANL-T2 is provided below. ANL- T2 BOARD Top View Bottom View... -
Page 18: Ac - Board - Ac-T1
AC - Board - AC-T1 The AC-T1 board provides AC filtering to protect the power supply and the control system from voltage spikes. This board contains the AC voltage drivers that control the AC devices in the system. This is done by accepting command signals indirectly from the DIG-T2 board through the ANL-T2 analog board and then turning the devices on or off. -
Page 19: Ac-T1 Board
AC-T1 BOARD Top View Bottom View... -
Page 20: Calibration Of Pressure And Temperature
CALIBRATION OF PRESSURE AND TEMPERATURE Calibration Overview The calibration of temperature and pressure is performed digitally. This system does not have adjustment pots. All calibrations are preformed through the keypad. The calibration procedure is identical on all EHS models. The electronic temperature and pressure measuring circuits built into the EHS are designed with components having 1% accuracy. -
Page 21: Calibration Theory - Error Compensation
Calibration Theory - Error Compensation: The system’s error compensation is based on a calculation involving two points. These points represent the low and high end of the autoclaves operating temperature or pressure range. Each point has two values; one value is the “A” actual (measured) reading of either temperature or pressure (from a PT simulator, independent thermometer or pressure gauge). - Page 22 5.4.2 Collecting and entering temperature data When collecting data, keep in mind that “A” is always the actual temperature and “R” is always what is being displayed on the digital screen of the autoclave. Once in the calibration mode, the calibration screen will look similar to this: Upper Row: A 140.0 R 140.0 (lower temp reading °F)
- Page 23 — Enter the value for “A”. This will be the second temperature value that the PT100 simulator was set for. — Press the PROGRAM key to advance to the next value. — The cursor on the bottom row will move one position to “R”.
- Page 24 — Using the UP/DN arrow keys raise the value of “R” if the display reads high. Lower the value of “R” if the display reads low. (Example: if the display reads 2 psi, then raise the value of “R” by 2; if it reads 2Ih then lower the value of “R”...
- Page 25 — Press the PROGRAM key to advance to the next value. — The cursor on the bottom row will move one position to “R”; now enter the pressure value recorded from the digital display to which you have already added 14.5. —...
- Page 26 5.4.4 Accessing the calibration mode — With the unit turned on press the PROGRAM key. — Pressing the PROGRAM key will bring you to its first function of setting the system’s date the time. — Setting the date and time can be bypassed by pressing the PROGRAM key six times.
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Page 27: Testing And Resetting
TESTING AND RESETTING Test Points These test points are provided to assist in trouble shooting the autoclave. A test point board is needed to be able to read these test points. FUNCTION NU TP VALVE +5V DC +12V DC OUTPUT HEATERS 0V-Off;... -
Page 28: In - Out Test Mode
In – Out Test mode: To enter the test mode – • Turn off the main power switch • While pressing and holding the UP arrow key, turn on the main power switch. The output test starts immediately Each output (valves, heaters, pumps), will be activated and the name of that device will be displayed. -
Page 29: Resetting The Autoclave
DISPLAYED ITEM ACTIVATED REMARKS NOTICE Electrode senses water above Electrd –l 0 minimum level in the jacket Electrode does sense water Low water level electrode above minimum level in the Electrd –l 255 jacket and disconnects heating elements Door Sw “0” Door switch activated Door switch Door Sw “1”... -
Page 30: Input Output Graph
Input Output Graph:... -
Page 36: Properties Of Saturated Steam
PROPERTIES OF SATURATED STEAM (From Baumiester & Marks “Standard Handbook for Mechanical Engineers” 7th Edition) Gauge Absolute Gauge Absolute Temp °F Temp °F Pressure Pressure Pressure Pressure 14.7 212.00 274.44 213.03 275.80 216.32 277.13 217.44 278.45 222.41 279.74 225.24 281.01 227.96 282.26 230.57... -
Page 37: Software Programming Parameters
SOFTWARE PROGRAMMING PARAMETERS General The software version that runs the control system of the EHS autoclave can be found by turning the unit on and watching the display. The version number is also printed if a printer is installed. The software contains a table of parameters of which some of them define the autoclave, and some of them define the processes in the autoclave. - Page 38 8.2.1 SteTemp – Temperature required for sterilization This parameter will set the desired temperature for sterilization Access Code Resolution 1ºF Minimum value 250ºF Maximum value 280ºF Cycle Default Values Value 8.2.2 Ster Time – Time required for sterilization This parameter will set the time desired for sterilization Access code Resolution 1 minute...
- Page 39 8.2.5 Ex.Mode – Rate of steam discharge during the exhaust stage This parameter sets the rate at which steam is discharged during the exhaust stage. Access Code Resolution Value 1 or 4 Fast Exhaust Slow Exhaust Cycle Default Values Value 8.2.6 End Temp –...
- Page 40 – 8.2.8 Vac dip1 Vacuum value of the first vacuum pulse This parameter sets the value of the vacuum that pulse no.1 needs to achieve in the prevacuum stage. This parameter is expressed in psia (atmospheric pressure at sea level is = 14.7psia).
- Page 41 – 8.2.11 VacTime2 Waiting time at the end of each of the remaining pulses This parameter sets the wait time at the end of each of the remaining vacuum pulses, during the prevacuum stage. After reaching VacDip2, there is a waiting time to allow the unit to stabilize.
- Page 42 – 8.2.13 limitP add defines the upper limit of the pressure in the jacket This parameter is designed as a safety measure that defines the maximum pressure in the jacket during heating and sterilization stages. The maximum working pressure in he jacket is defined as the pressure that correlates to the sterilization temperature + 5.4°F.
- Page 43 8.2.15 ReqPrs+ - Overrides the pressure calculated for sterilization This parameter is used to insure that during sterilization the temperature is correctly maintained. It does this by raising the value of the sterilization pressure necessary to maintain a sterilization temperature. The sterilization pressure is calculated by the unit based upon the SteTemp parameter.
- Page 44 – 8.2.16 Dry Vac Pressure during the Dry Stage This parameter is intended to control the vacuum pressure during the Drying Stage. It does this by opening and closing the Air Inlet Valve. In all cases the vacuum pump runs continuously and the Jacket is heated until the end of the Dry stage, as set by the Dry time parameter.
- Page 45 – 8.2.17 Atmos. Press Atmospheric Pressure This parameter tells the unit the atmospheric pressure of the location in which it is installed. The pressure entered must be with in 5% of the actual atmospheric pressure for that location. Unlike the other parameters you only need to enter this parameter once in any one cycle and all cycles will be updated.
- Page 46 8.2.19 Heat Step – sterile temperature overshoot control This parameter is used to reduce overshoot of the sterilization temperature by controlling the sterilization pressure. The sterilization pressure is calculated by the unit based upon the SteTemp parameter. When the cycle starts the heating rate in the chamber is constant until the pressure in the chamber reaches the sterilization pressure minus the Heat Step.
- Page 47 8.2.22 Flash – Heating over-pressure control This parameter is designed to regulate over pressure during the heat up stage. The system constantly monitors the temperature and pressure and compares both values to the Saturated Steam Curve. If the pressure is found to exceed the corresponding temperature by more than 0.7 psi then the fast exhaust valve is opened for 1 second in an attempt to realign the temperature and pressure.
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Page 48: Maintenance And Replacement Procedures
MAINTENANCE AND REPLACEMENT PROCEDURES Safety Tests after Repair ATTENTION! After every repair or dismantling of the enclosure, it is recommended that the following tests be performed: 1. Enclosure Current Leakage Test. The test should be performed using a Megger. Make sure the autoclave is unplugged. -
Page 49: Removing The Autoclave's Outer Covers
Removing the Autoclave’s Outer Covers Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the chamber or jacket. Allow the autoclave to cool before removing outer covers. 1. Remove the screws holding the rear cover (1). 2. -
Page 50: Replacing The Safety Valve
Replacing the Safety Valve The safety valve is installed to protect the Jacket from over pressurizing should all the electrical controls fail. Caution! Before starting, be sure that the electric cord is disconnected and that there is no pressure in the chamber or jacket. 1. -
Page 51: Replacing The Dig-T2 Board
Replacing the DIG-T2 board The DIG-T2 board contains the software program and controls all the functions of the autoclave. See sec 4.3. Caution! Make sure that the power cord is disconnected! Allow the chamber and jacket to cool before removing outer covers. Refer to the picture below when following this procedure. - Page 52 Electronic Control panel Electronic box: 2540 Electronic Control panel Electronic box: 3870...
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Page 53: Drain Valve Repair
Drain Valve Repair There are two drain valves on the front of the autoclave. One drains the mineral free water from the front section of the reservoir and the other drains the vacuum pump water from the back section of the reservoir. Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the chamber or jacket. - Page 54 9.5.2 Replacing the drain valve assembly Take off the autoclave cover (see para. 9.2 “Removing the Outer Covers of the Autoclave”). Disconnect the drain tube from the valve, using a 9/16” wrench. Remove the nut (3) and the “ring for drain valve” (2). Remove the drain valve (1) from the panel.
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Page 55: Replacing The Pressure Gauge
Replacing the Pressure Gauge Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the autoclave’s chamber and jacket. 9.6.1 Model 2540 Take off the door cover (see para. 9.18 Replacement of the Door Cover). -
Page 56: Replacing The Door Bellows (Located In The Door Bridge)
Replacing the Door Bellows (Located in the door bridge) The door bellows is designed to work with the closing device providing a double lock that keeps the door closed while there is pressure inside the chamber. Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the autoclave’s chamber. -
Page 57: Replacing The Printer
Replacing the Printer Caution! Before starting, disconnect the instrument from the power source. 1. Take off the autoclave cover (see para. 9.2 “Removing the Autoclave’s Outer Covers ”). 3. Disconnect the flat cable (1) connecting the printer to the DIG-T2 board. -
Page 58: Replacing The Door Switch
Replacing the Door Switch The door switch is designed to ensure that the door is properly closed before and during a cycle. Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the autoclave’s chamber. 1. -
Page 59: Replacing The Circuit Breaker
Make sure that the correct circuit breaker is installed as specified below: Model 2540 - 1 circuit breaker - 20A Model 3870 - 1 circuit breaker - 3 phase 20A. Circuit breaker Circuit breaker 3ph 20A Screw Model 2540 EHS Model 3870 EHS... -
Page 60: Replacing The Water Pump
9.11 Replacing the water pump The water pump supplies mineral - free water to the jacket of the autoclave from the front compartment of the reservoir. This water is used by the steam generator to produce steam for sterilization. The pump is protected from running dry and burning out, by the float switch mounted in the lower part of the front reservoir compartment. -
Page 61: Pressure Switch
9.12 Pressure Switch The Pressure Switch is designed as a safety device, limiting over- pressure in the steam generator. It is set to a pressure of 38 psig which is about 2 psi above the working pressure of the generator. The pressure switch is factory set and it should not be adjusted in the field. -
Page 62: The Heaters
9.13 The Heaters The autoclave contains internal submerged heaters, mounted at the bottom back side of the jacket (see drawing below). Model 2540 has three (3) 1000W / 208V heaters. Model 3870 has six (6) 1000W / 208V heaters. To replace heaters proceed as follows: Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the autoclave’s chamber... -
Page 63: The Dual Compartment Water Reservoir
9.14 The Dual Compartment Water Reservoir 9.14.1 Description The dual compartment water reservoir is one unit with a wall separating the two compartments. The front compartment holds the mineral free water required for the generation of steam in the jacket. Water enters at the top through a control valve from an external mineral-free water source. - Page 64 9.14.2 Replacement It is possible to replace individual damaged components on the reservoir. It is not necessary to replace the entire reservoir, however, if a complete replacement is needed follow the steps below. Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the autoclave’s chamber and jacket.
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Page 65: The Water Sensing Electrodes
9.15 The Water Sensing Electrodes The two electrodes that control the water level of the jacket are located in a stainless steel bottle, or housing, connected to the rear of the autoclave. The housing is connected to the jacket by upper and lower copper tubes, which allows the jacket water to flow in and out of the housing. -
Page 67: The Vacuum Pump
9.16 The Vacuum Pump 9.16.1 Description To produce the vacuum needed in the prevacuum and drying stages, the autoclave is equipped with a liquid ring pump. This pump is suitable for continuous operation, and achieving a high vacuum necessary for proper operation. To produce the needed vacuum the pump draws water from the reserve in the rear compartment of the water reservoir. -
Page 69: Draining The Jacket
9.17 Draining the Jacket Caution Before starting, ensure that the electric cord is disconnected and there is no pressure in the chamber or jacket. 1. Turn off the main switch. 2. Remove the rear cover. 3. Turn the valve handle (1) 1/4 turn and the jacket will begin to drain. -
Page 70: Replacement Of The Door Cover
9.18 Replacement of the Door Cover Caution: Before starting, be sure that the electric cord is disconnected from the power source and that there is no pressure in the autoclave chamber. 1. Unscrew the four screws attaching the door cover and remove the door cover. -
Page 71: Replacing The Closing Device
9.19 Replacing the Closing Device Caution: Before starting, verify that there is no pressure in the autoclave chamber. 1. Remove the “C” clip (9) from the bottom of the door locking pin (6). Newer models will have a cotter pin. 2. -
Page 72: Pt100 Temperature Sensor Replacement
9.20 PT100 Temperature Sensor Replacement The temperature sensor is located below the chamber at the front. It is mounted in a fitting (1) that is part of the chamber drain system (see picture below). Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the autoclave’s chamber and jacket. -
Page 73: Troubleshooting
TROUBLESHOOTING 10.1 Preliminary Check Before performing any troubleshooting operation and before removing the autoclave’s cover, check the following: 1. Electrical power: Verify that: a. Power supply is 1ph/208 VAC for model 2540 and 3ph/208 VAC for model 3870. b. It has an earth wire. 2. -
Page 115: Spare Parts List
SPARE PARTS LIST DESCRIPTION 2540 EHS 3870 EHS 1. Gauge, Pressure, Steam, -30+60 psi, 1.5" GAU029-0009 GAU029-0009 2. Switch, Rocker, 16A ELE035-0012 ELE035-0012 3. Circuit breaker 3-PH, 20A, Carlingswitch ELE035-0053 4. Circuit Breaker, 1-PH, 25A, Carlingswitch ELE035-0060 5. Thermostat, CUT-OFF, Campini THE005-0008 THE005-0008 6. - Page 116 DESCRIPTION 2540 EHS 3870 EHS 31. Valve, Manual Ball, Mini, 1/4" VLV170- 0055 VLV170- 0055 32. Pump, Water, EX7, 220v, Ulka PUM055-0010 PUM055-0010 Pump, Vacuum, Water Ring, V6, 110V, PUM057-0000 PUM057-0000 Speck 34. Valve, Solenoid, 12VDC-12W, ASCO SOL026-0023 SOL026-0023 35. Switch, Pressure, TY85, Campini...
- Page 117 DESCRIPTION 2540 EHS 3870 EHS Check Valve, Spring Disk, 1/4", St.St., ARM172-0007 ARM172-0007 Mondeo 62. Strainer, water, Y type, 1/4", 192, Itap FIL176-0028 FIL176-0028 63. Shock Absorber, 9/12, 6mm, V6, V30 SKR203-0003 SKR203-0003 64. Shock Absorber, ULKA Pump SKR203-0006 SKR203-0006 65.
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Page 118: External Connection Of The 2540Ehs Autoclaves
EXTERNAL CONNECTION OF THE 2540EHS AUTOCLAVES ELECTRONICS BOX Valves & Solenoids drivers PC Communication Port Digital Input & Electrodes Test Points Connector Chamber temperature sensor Jacket Pressure sensor Chamber Pressure sensor Pressure switch & Low Float of Vacuum Pump Reservoir Vacuum Pump AC Control Heater Elements AC Control Power Inlet 220VAC/60Hz... -
Page 119: External Connection Of The 3870Ehs Autoclaves
EXTERNAL CONNECTION OF THE 3870EHS AUTOCLAVES ELECTRONICS BOX Valves & Solenoids drivers PC Communication Port Digital Input & Electrodes Test Points Connector Chamber temperature sensor Jacket Pressure sensor Chamber Pressure sensor Pressure switch & Low Float of Vacuum Pump Reservoir Cut Off Switch Connection Heater Elements AC Control Power Inlet 220VAC/60Hz... -
Page 120: Vessel Assembly
VESSEL ASSEMBLY Model 2540 EHS Model 3870 EHS... -
Page 121: Outer Cabinet - Assembly
OUTER CABINET – ASSEMBLY Model 2540 EHS Model 3870 EHS... -
Page 122: Tray Holder
TRAY HOLDER For model 2540 (TRH254-0009) For model 3870 (TRH387-0001) -
Page 123: Tray
TRAY MODEL SIZE CAT. No. 2540 TRY240-0001 TRY387-0001 3870 Small TRY387-0003 TRAY HANDLE (CMT240-0001) -
Page 124: Door Tightening Bolt - Assembly
DOOR TIGHTENING BOLT – ASSEMBLY Cat. No. Description 2540 3870 Bushing LOK240-0003 LOK387-0003 Door tightening bolt assembly LOK240-0036 LOK387-0007 Locking screw housing LOK240-0005 LOK387-0006 Locking base LOK240-0012 LOK387-0012 Locking housing axe LOK240-0014 LOK387-0014 Door locking device pin LOK240-0019 LOK387-0016 Bakelite handle HAN071-0003 HAN071-0006 Closing bridge “c”... -
Page 125: Valves Numbering
VALVES NUMBERING The valves in the drawing and the manual are numbered according to their function. The following list includes all the valve numbers that are in use in this manual Size mm 2540 3870 13. Feed water – cool fast exhaust 14. -
Page 126: Piping Drawing For 2540 Ehs
PIPING DRAWING FOR 2540 EHS... -
Page 127: Piping Drawing For 3870 Ehs
PIPING DRAWING FOR 3870 EHS... -
Page 128: Electrical Drawing For 2540 Ehs
ELECTRICAL DRAWING FOR 2540 EHS... -
Page 129: Electrical Drawing For 3870 Ehs (Till S/N 2307039)
ELECTRICAL DRAWING FOR 3870 EHS (TILL S/N 2307039) -
Page 130: Electrical Drawing For 3870 Ehs (After S/N 2307040)
ELECTRICAL DRAWING FOR 3870 EHS (AFTER S/N 2307040)
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