Tuttnauer 2540 Operation & Maintenance Manual
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Tuttnauer 2540 Operation & Maintenance Manual

Tuttnauer 2540 Operation & Maintenance Manual

Electronic table - top autoclaves (with cooling option)
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OPERATION
&
MAINTENANCE
MANUAL
Electronic Table - Top Autoclaves
(With cooling option)
Models
2540, 3150, 3850, 3870, 5050, 5075 EL
Cat. No. MAN205-0035000EN Rev AA
 Tuttnauer Europe B.V., Hoeksteen 11 4815 PR P.O. Box 7191 4800 GD Breda, The Netherlands
 Tel: 31 (0) 765423510,  Fax: 31 (0) 765423540

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Summary of Contents for Tuttnauer 2540

  • Page 1 (With cooling option) Models 2540, 3150, 3850, 3870, 5050, 5075 EL Cat. No. MAN205-0035000EN Rev AA  Tuttnauer Europe B.V., Hoeksteen 11 4815 PR P.O. Box 7191 4800 GD Breda, The Netherlands  Tel: 31 (0) 765423510,  Fax: 31 (0) 765423540...

  • Page 3: Table Of Contents

    Environment Emission Information.............. 10 Directives and Standards................. 10 Electrical Data ....................10 3.10 Overall Dimensions Model 2540 EL.............. 11 3.11 Overall Dimensions Models 3150 EL ............12 3.12 Overall Dimensions Models 3850, 3870 EL ..........13 3.13 Overall Dimensions Models 5050, 5075 EL ..........14 3.14 Loading Capacities...................
  • Page 4 Cleaning water strainer ................... 50 Checking the Safety Valve................51 Replacing the Door Gasket ................53 Door Safety System for models 2540, 3150, 3850, 3870 ......54 Door Safety System for models 5050, 5075........... 55 Cleaning Table Top Autoclaves with Chamber Brite™......58 TROUBLESHOOTING.....................
  • Page 5 TABLE OF CONTENT (Cont.) DRAWINGS PAGE NO. Front View ..........................19 Rear View Model 2540 ......................20 Rear View Models 3150, 3850, 3870 ................. 21 Rear View Models 5050, 5075 .................... 22 Front Panel Keyboard ......................29 Pouch Rack........................... 62 Tray - Standard ........................

  • Page 6: General

    If damage is apparent, contact your dealer or point of purchase, so that they may notify the manufacturer and file a claim with the appropriate carrier. All Tuttnauer 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.
  • Page 7 No autoclaves will be accepted for repair without proper authorization from us. All transportation charges must be paid both ways by the owner. This warranty will be void if the unit is not purchased from an authorized full service Tuttnauer dealer. Page 5 of 66 Pages...

  • Page 8: Safety Instructions

    SAFETY INSTRUCTIONS The autoclave has unique characteristics. Please read and understand the operation instructions before first operation of the autoclave. The following issues may require instructions guidance provided by the manufacturer: how to operate the autoclave, the door safety mechanism, the dangers involved in circumventing safety means, how to ensure that the door is closed, and how to select a correct sterilization program.
  • Page 9 Once annually, or more frequently, effective tests must be performed, i.e., calibration and validation. Examine the condition of assemblies on a regular basis. Make sure there are no leaks, breaks, blockages, whistles or strange noises. It is required to conduct maintenance operations as instructed. Immediately notify the person in charge of any deviation or risk for the proper function of the device.

  • Page 10: General Information

    GENERAL INFORMATION Introduction Models 2540, 3150, 3850, 3870, 5050 and 5075 EL are table-top sterilizers designed especially for the sterilization of instruments, liquids, and other materials in hospital laboratories, medical laboratories, research institutes, food laboratories and pharmaceutical facilities. A computerized control unit ensuring a fully automatic sterilization cycle controls the autoclave.

  • Page 11: Operating Conditions

     Chamber and door are made of stainless steel  Trays are made of stainless steel.  Water reservoirs of models 2540, 3150, 3850, 3870 are made of hard plastic material.  Water reservoirs of models 5050, 5075 are made of stainless steel.

  • Page 12: Environment Emission Information

    3. Electromagnetic Compatibility Requirements Directive 89/336/EC. 3.8.2 Technical Standards 1. ASME code (models 2540, 3150, 3850, 3870, 5050, 5075). 2. EN 13445 (models 5050, 5075). 3. IEC-61010-1 & IEC-61010-2-041 - Safety requirements for medical device. 4. EN 61326 – EMC Requirements .

  • Page 13: Overall Dimensions Model 2540 El

    3.10 Overall Dimensions Model 2540 EL 14.4 Overall Dimensions 20.0 21.5 35.8 Maximum dimensions (door open) 25.8 16.4 Distance between supporting legs 16.6 F1 – front legs F - rear legs 15.8 diameter Chamber Depth 16.5 Reservoir volume 3.0 lit.

  • Page 14: Overall Dimensions Models 3150 El

    3.11 Overall Dimensions Models 3150 EL 23.6 Overall Dimensions 17.7 27.4 1120 44.1 Maximum dimensions (door open) 28.7 14.6 Distance between supporting legs 19.3 F1 – front legs F - rear legs 20.3 diameter 12.2 Chamber Depth 19.7 Reservoir volume 6.0 lit.

  • Page 15: Overall Dimensions Models 3850, 3870 El

    3.12 Overall Dimensions Models 3850, 3870 EL Model 3850 3870 Dimensions 26.0 26.0 Overall Dimensions 20.7 20.7 27.5 34.5 1155 45.5 1335 53.0 Maximum dimensions (door open) 32.0 32.0 17.7 17.7 Distance between 22.2 22.2 supporting legs F1 – front legs F - rear legs 21.8 30.5...

  • Page 16: Overall Dimensions Models 5050, 5075 El

    3.13 Overall Dimensions Models 5050, 5075 EL Model 5050 5075 Dimensions 34.6 34.6 Overall 28.7 28.7 Dimensions 32.1 1045 41.1 Maximum 1440 56.7 1640 64.6 dimensions 31.6 31.6 (door open) 24.7 24.7 Distance between supporting legs 23.4 32.4 diameter 19.7 19.7 Chamber Depth...

  • Page 17: Loading Capacities

    3.14 Loading Capacities 3.14.1 Erlenmeyer Flasks Type 2540 3150 3850 3870 5050 5075 250 ml 500 ml  1000 ml   2000 ml   3000 ml     5000 ml 3.14.2 Medium Flasks (Schott) Type 2540...

  • Page 18: Technical Specifications El

    Page 16 of 66 Pages...

  • Page 19: Water Quality

    3.17 Water quality 3.17.1 Water for generating steam The distilled or mineral – free water supplied to the autoclave should have the physical characteristics and maximum acceptable level of contaminants indicated in the table below: Physical Characteristics and Maximum acceptable contaminants levels in steam for sterlizers (According to EN 13060:2004).
  • Page 20 RO is cheaper to install and to run than DI. RO removes particulate matter, organic molecules and pyrogens that DI cannot remove RO water is less corrosive to steel and copper than DI water. RO maintenance requirements are less demanding than those of the DI units.

  • Page 21: Front View

    Door closing device Door switch Autoclave cover Water reservoir cover Water reservoir – assembly Safety valve Model 2540 Air relief valve 10 Pressure gauge 11 Validation port (under door cover) 12 Main switch 13 Printer 14 Front panel key board...

  • Page 22: Rear View Model 2540

    REAR VIEW MODEL 2540 Page 20 of 66 Pages...

  • Page 23: Rear View Models 3150, 3850, 3870

    REAR VIEW MODELS 3150, 3850, 3870 Page 21 of 66 Pages...

  • Page 24: Rear View Models 5050, 5075

    REAR VIEW MODELS 5050, 5075 Page 22 of 66 Pages...

  • Page 25: Sterilization Programs

    STERILIZATION PROGRAMS The autoclave offers 6 sterilization programs, with or without drying stage. Program 1 – Unwrapped Instruments (1 – Instruments) Program 1 is recommended for sterilizing unwrapped instruments and materials for immediate use and preventing cross infection at temperature 134ºC.

  • Page 26: Program 2 (2- Instruments)

    Program 2 (2- Instruments) For instruments and materials when the manufacturer recommends autoclaving at temperatures of up to 121º C with a drying cycle. Nominal parameters  Sterilization temperature: 121º C (250º F).  Sterilization time: 15 minutes.  Drying time: 15 minutes. Operations Sequence ...

  • Page 27: Program 3 (3 -Waste)

    Program 3 (3 –Waste) For waste materials when the manufacturer recommends autoclaving at a temperature of 121º C with a drying cycle. Nominal Parameters  Sterilization temp.: 121º C (250º F).  Sterilization time: 20 minutes.  Dry time: 5 minutes. Operations Sequence ...

  • Page 28: Program 4 (4 - Liquids)

    Program 4 (4 – Liquids) For liquids when the manufacturer recommends autoclaving at temperatures of 121º C with no drying cycle. Nominal Parameters  Sterilization temperature: 121º C(250º F).  Sterilization time: 20 minutes. Operations Sequence  Heating phase; The water enters the chamber and heats up until the sterilization temperature is reached.

  • Page 29: Program 5 (5- Liquids)

    Program 5 (5- Liquids) For liquids when the manufacturer recommends processing at temperatures of 105º C with no drying cycle. Nominal Parameters  Temperature:105º C  Time: 18 minutes. Operations Sequence  Heating phase; The water enters the chamber and heats up until the sterilization temperature is reached.

  • Page 30: Program 6 (6 - Liq+Cool)

    Program 6 (6 – liq+Cool) For materials when the manufacturer recommends processing at temperatures of 121º C and cooling to temperatures of 85º C with no drying cycle. Nominal Parameters  Sterilization temperature: 121º C  Sterilization time: 30 minutes. Operations Sequence ...

  • Page 31: Keyboard (Keys And Display)

    KEYBOARD (keys and display) Front Panel Keyboard Page 29 of 66 Pages...

  • Page 32: Description And Functions Of The Front Panel Keyboard

    Description and Functions of the Front Panel Keyboard The command panel is comprised of 3 sections, on the lower section there are 6 keys; 3 command keys and 3 programming keys. The middle section consists of the LCD display with two rows and 16 characters on each line.
  • Page 33 3. Start/ Stop key This key commands the following 3 functions:  Starting the process.  Stopping the process.  Canceling the FAIL message from the command panel and opening the electric door locking if available. Note: “STOP” does not operate in EXH stage. Starting the process: It is active while the autoclave is in standby position, if the door is closed and water level in the reservoir is normal, pressing this...
  • Page 34 UP key This key enables increasing the value displayed above the cursor, at the clock programming and for setting of certain parameters by the technician. DN key This key enables decreasing the value displayed above the cursor, at the clock programming and for setting of certain parameters by the technician.

  • Page 35: Description Of The Display

    Description of the Display The display is built of 2 rows, each row consists of 16 characters. 5.2.1 The upper row  ST. BY (STAND BY) – not in operation.  HEAT – heating stage.  STER (STERILIZATION) – sterilization stage. ...
  • Page 36  At the sterilization and dry stage, the countdown time left to completion of the stage is displayed in the interval between the readouts of temperature and pressure, on the lower row.  The format of the display is MM:SS (two digits for minutes and two digits for seconds).

  • Page 37: Description Of Displayed Messages And Safety Measures

    Description of Displayed Messages and Safety Measures Message is displayed, fail indicator lights and cycle is Low Temp. aborted, if the temperature drops for more than 5 seconds below the required sterilization temperature. Message is displayed and sterilization does not start if the Low Heat autoclave has not reached sterilization temperature after heating for 60 minutes (slow exhaust program), and 30...
  • Page 38 Door Unlock Message is displayed and the DOOR CLOSED, LED indicator flashes if the door is improperly closed. The START button is pressed to start the desired cycle. If the door accidentally opens during any stage of the cycle, the same message and indicator appears, and the system reacts as if the STOP key was pressed.

  • Page 39: Printer

    PRINTER The printer is an optional device. If the autoclave is not equipped with a printer paragraph 5 is not applicable. Printer Operation 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).
  • Page 40 PRINTER OUTPUT DESCRIPTION Autoclave:1 Number of autoclave. Operator :___________ To be filled in manually by operator. 11/02/2001 12:22:53 Date and time sterilization cycle ended. Load number: 00004 Load number. Useful to determine when to clean the chamber. Cycle ended  D53:53 099.7°C 096.5k The time, temperature and pressure during drying.

  • Page 41: Dpu-20 Printer Handling

    DPU-20 Printer Handling If the autoclave is equipped with a DPU-20 printer refer to this paragraph. The printer is driven and controlled automatically by the control unit, while the autoclave performs a sterilization program. Figure 1 Figure 2 To set the paper roll in the printer perform the following steps: 6.2.1 Gently push the clips for removing the front panel, remove the panel and pull out the printer gently.

  • Page 42: Dpu 30 Printer Handling

    DPU 30 Printer Handling 6.3.1 Setting Paper If the autoclave is equipped with A DPU 30 printer, follow the instructions in this paragraph. 1. Press the paper cover open button, and open the paper cover. Handle the paper cutter carefully not to cut your hand. 2.

  • Page 43: Preparation Before Sterilization

    PREPARATION BEFORE STERILIZATION The purpose of packaging and wrapping of items for sterilization is to provide an effective barrier against sources of potential contamination in order to maintain sterility and to permit aseptic removal of the contents of the pack. Packaging and wrapping materials should permit the removal of air from the pack, penetration of the sterilizing water vapor into the pack and removal of the sterilizing vapor.
  • Page 44 For model 2540 For model 3870 2. It is highly recommended to utilize the Tuttnauer Pouch Rack. This rack allows the operator to place pouches on their side, thus increasing the capacity of the autoclave significantly and promoting better drying of the instruments.
  • Page 45 Packs 1. Place packs upright on the tray, side by side. 2. Packs should not touch the chamber walls. 3. Pack instrument sets in a manner that prevents damage to delicate items. 4. Pack hollowware sets so that all openings face the same direction and so that the contents cannot move inside the pack.

  • Page 46: Filling The Water Reservoir

    The water quantity for 2540 is approx. 3 liters (0.66 US gal.) and for models 3150, 3850, 3870 is approx. 7.1 liters (1.56 US gal.).

  • Page 47: Operating Instructions

    If not - insert as per para. 5.2. 8. Load the material to be sterilized into the chamber, and close the door. Note (for models 2540, 3140, 3850, 3870): Due to inherent elasticity of the door gasket, the...

  • Page 48: Loading And Unloading The Device

    !!!” message will be printed and the buzzer FAIL will output an interrupted sound. 13. Open the door and unload the sterilized material from chamber. 13.1For models 2540, 3150, 3850, 3870, in case of fail press the key to cancel the locking of the door. START STOP 13.2For models 5050, 5075, to release the door locking at the end of...
  • Page 49 8.2.3 Unloading On completion of the cycle, take out the load immediately from the sterilizer. Do not remove the load from the tray until its temperature reduces to the room temperature. Let the load cool down in an area without air movement (air conditioning, etc.) and with minimum people passing by to avoid possibility of touching the hot load.

  • Page 50: Maintenance Instructions

    MAINTENANCE INSTRUCTIONS Preventive and Scheduled Maintenance The maintenance operations described in this chapter have to be fulfilled periodically to keep the device in good condition and to reduce the breakdown time to a minimum. The user maintenance personnel can easily execute these operations in accordance with further instructions.

  • Page 51: Draining The Reservoir

    Draining the Reservoir Caution! Before starting, Make sure that the electric cord is disconnected and there is no pressure in the autoclave. 1. Connect the supplied plastic tube and turn drain valve counter clockwise (1 turn). 2. When the water reservoir is empty, turn drain valve clockwise to the clockwise position.

  • Page 52: Cleaning Water Strainer

    Cleaning water strainer Caution! Before proceeding, Make sure that the electric cord is disconnected and there is no pressure in the autoclave. 1. Open the strainer cover. 2. Remove the strainer element. 3. Rinse the strainer with water. Use a brush if necessary. 4.

  • Page 53: Checking The Safety Valve

    In order to prevent the safety valve from blockage, it is necessary to allow the steam pressure to escape through it (every month). On models 2540, 3150, 3850, 3870 the safety valve is located in the water reservoir. On models 5050, 5075 the safety valve is located in the rear top side of the autoclave.
  • Page 54 3. Remove water reservoir cover 4. Operate the safety valve: On models 2540, 3150, 3850, 3870 pull the ring of the safety valve using a tool, i.e. screwdriver, hook etc and lift the safety valve ring for 2 seconds. Be careful not to burn your hands.

  • Page 55: Replacing The Door Gasket

    Replacing the Door Gasket For models 2540, 3150, 3850, 3870 (Gaskets of models 5050, 5075 shall be replaced by a technician. See technician manual) Pull off the gasket from the door groove and install the new gasket referring to the drawings as above points 1, 2 and 3.

  • Page 56: Door Safety System For Models 2540, 3150, 3850, 3870

    Door Safety System for models 2540, 3150, 3850, 3870 The door opening is ensured by two means: 1. The closing device prevents an incidental opening of the door. 2. A pull-type solenoid, which is in inactivated position, locks the door and must be electrically powered to release the locking and enable the opening of the door.

  • Page 57: Door Safety System For Models 5050, 5075

    Door Safety System for models 5050, 5075 9.7.1 Door Components  A circular frame with a “C” cross section is welded on the topside of the vessel. When the door is closed it lays on the “bottom leg” of the frame. ...
  • Page 58 9.7.2.2 Safety locking microswitch (10) This microswitch is activated when the arms are in a radial – “locked” position. The microswitch signal one of the following: a. Arms are locked – cycle can be activated b. Arms are in a non-locked position It is impossible to start a cycle and the door can be opened.
  • Page 59 9.7.2.4 Safety opening device (11) This Safety device is a 3/2 operating pneumatic spring loaded valve (2 position, 3 ports) that is connected to the safety port of the door. An angular bracket (12), which is attached to one of the arms, will push the valve’s piston to a position that at the instant that the arms are locked, the safety port of the door is blocked.

  • Page 60: Cleaning Table Top Autoclaves With Chamber Brite

    released and valve opens, chamber is aerated and residual pressure discharged from the chamber. This way, the second step, opening the door by pulling it, can be done safely, with no risk for the operator, of steam or hot water burst. After the ”door light”...
  • Page 61 MSDS available upon request. For models 2540 use one packet of CHAMBER BRITE™. For models 3150, 3850, 3870 use two packets of CHAMBER BRITE™. For models 5050, 5075 use three packets of CHAMBER BRITE™.

  • Page 62: Troubleshooting

    Page 60 of 66 Pages...
  • Page 63 Page 61 of 66 Pages...

  • Page 64: Pouch Rack

    POUCH RACK Page 62 of 66 Pages...

  • Page 65: Tray - Standard

    For model 2540 - ACS215-0008 For model 3870- TRH387-0006 TRAY - standard MODEL CAT. No. 2540 TRY254-0001 3850 TRY385-0006 3150 TRY315-0001 3870 TRY387-0006 5050 TRY505-0001 5075 TRY507-0001 Page 63 of 66 Pages...

  • Page 66: Tray, Special Elc Version

    TRAY, Special ELC version MODEL CAT. No. 2540 TRY254-0001 TRAY HOLDER, Special ELC version MODEL CAT. No. 2540 TRH234-0001 Page 64 of 66 Pages...

  • Page 67: Baskets And Containers

    Capacity L x D x H (mm) Capacity 400 x 170 x 140 400 x 170 x 140 2540 500 x 210 x 185 500 x 210 x 185 3150 500 x 260 x 225 500 x 260 x 225...

  • Page 68: Spare Parts List

    SPARE PARTS LIST Cat. No. Description 2540 3150 3850 3870 5050 5075 Strainer element, FIL175-0046 FIL175-0046 FIL175-0046 FIL175-0046 FIL175-0046 FIL175-0046 400µ Cap for¼” strainer FIL175-0027 FIL175-0027 FIL175-0027 FIL175-0027 FIL175-0027 FIL175-0027 Door gasket   GAS080-0003 GAS080-0029 GAS080-0004 GAS080-0004 Teflon gasket 4mm...

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