Page 1 Cat. No.: MAN205-0195042EN Rev A Aug. 2011  Tuttnauer. Ltd., Har Tuv Industrial Zone, B P.O. Box 170, Beit Shemesh, 99000, Israel,  Tel:972 2 9904611  Fax:972 2 9904730  Tuttnauer Europe b.v., Hoeksteen 11, 4815 PR Breda Breda, P.O. Box 7191, 4800 GD Breda, Netherlands.
Page 2 Web site: http//www.tuttnauer.com...
Page 3: Table Of Contents
Table of Contents INCOMING INSPECTION --------------------------------------------------------------------------- 1 SAFETY INSTRUCTIONS --------------------------------------------------------------------------- 2 GENERAL INFORMATION 1.1 Introduction --------------------------------------------------------------------------------------- 4 1.2 Front Panel --------------------------------------------------------------------------------------- 8 1.3 Standards ----------------------------------------------------------------------------------------- 9 1.4 Specifications ------------------------------------------------------------------------------------ 9 1.5 Symbol Descriptions --------------------------------------------------------------------------- 10 1.6 Utility Labels -------------------------------------------------------------------------------------- 10 INSTALLATION 2.1 Environmental Conditions -------------------------------------------------------------------- 11 2.2 Mounting ------------------------------------------------------------------------------------------- 11...
Page 4 Table of Contents (Cont.) 3.3 The Pneumatic Control System ------------------------------------------------------------- 25  Pneumatic Control System Drawing ------------------------------------------------------- 26 3.4 Absolute Pressure Transducers ------------------------------------------------------------- 27 3.5 The Vacuum Pump and the Heat Exchanger -------------------------------------------- 28 3.6 The Electrical System -------------------------------------------------------------------------- 29 3.7 The Control System ---------------------------------------------------------------------------- 31 ...
Page 5 Table of Contents (Cont.) 4.3.4 Changing Cycle Parameters ------------------------------------------------------ 52 4.3.5 Door Display Function -------------------------------------------------------------- 57 4.3.6 Display During a Cycle -------------------------------------------------------------- 58 PRINTER 5.1 Printer Output ------------------------------------------------------------------------------------ 59 5.2 Printer Handling --------------------------------------------------------------------------------- 61 STERILIZATION PROGRAMS 6.1 Program Descriptions -------------------------------------------------------------------------- 63 PREPARATION BEFORE STERILIZATION -------------------------------------------- 70 7.1 Loading -------------------------------------------------------------------------------------------- 71 7.2 Un-loading ---------------------------------------------------------------------------------------- 72...
Page 6 Table of Contents (Cont.) 9.6 The SHURFLO Water Pump Rear Endbell Replacement Kit ----------------------- 93 9.7 Generator Maintenance ----------------------------------------------------------------------- 95 9.7.1 Generator Pressure Switches ----------------------------------------------------- 95 9.7.2 Cleaning and Replacing the Water Level Electrodes ----------------------- 96 9.7.3 Replacing the Heaters -------------------------------------------------------------- 98 9.7.4 Replacing the Generator Side Gauge Glass Indicator Tube -------------- 99 9.8 Releasing the Vacuum Pump Rotor-------------------------------------------------------- 100...
Page 7: Incoming Inspection
INCOMING INSPECTION Upon receipt, the autoclave should be unpacked and inspected for mechanical damage. Observe packing method and retain packing material until the unit has been inspected. Mechanical inspection involves checking for signs of physical damage such as: scratched panel surfaces, broken knobs, etc. If damage is apparent, file a claim with the carrier.
Page 8: Safety Instructions
Safety Instructions The autoclave has unique characteristics. Please read and understand the operation instructions provided by the manufacturer before the first operation of the autoclave. The following issues may require clarification: The operation of the autoclave; the door safety mechanism; the door closing mechanism; the dangers involved in circumventing safety means;...
Page 9 Individual glass bottles may be placed within an appropriate container that will be placed on a tray. Never place glass bottles on the floor of the autoclave. Never fill more than 2/3 of the bottle volume. On closing the autoclave door, make sure that it is properly locked before activating.
Page 10: General Information
GENERAL INFORMATION Introduction This autoclave is 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 range of up to 137C (279ºF) and pressure up to 2.3 bar (34 psi). The autoclave is equipped with a 36 kW built-in steam generator.
Page 11  After opening the door on the dirty side, even after closing it and it being locked and sealed, the door on the clean side can be opened only after performing a complete sterilization cycle.  If cycle failed, the front door only can be opened. ...
Page 12 The pressure gauges: Front Panel Service Area Door 1 gasket pressure Chamber pressure Door 2 gasket pressure Jacket pressure Steam generator pressure The safety devices: RT112 pressure switch – (prevents the opening of the door if there is pressure in the chamber) Two ALCO pressure switches –...
Page 13 Warning! Do not operate the autoclave in the presence of dangerous gases and vapors. It is strictly forbidden to enter the autoclave chamber! If, for any reason (for cleaning, maintenance or if something falls down), it is necessary to enter the chamber, the person must lock the system by pressing the emergency switch and take the key with him to prevent accidents and unauthorized use.
Page 14: Front Panel
Front Panel Legend: 1. Pressure Gauges 2. Emergency STOP Switch 3. Operation Panel 4. Printer 5. Operating Switch 6. Steam Selector Switch 7. Chamber 8. Service Access Panel MAN205-0195042EN Rev. A Aug. 2011 Page 8 of 137 pages...
Page 15: Standards
Standards Tuttnauer. Ltd. company meets the provisions of the Medical Device Directive 93/42EEC and PED 97/23EEC and the following standards: ASME American Society of Mechanical Engineers Section VIII, Division 1, for unfired pressure vessels. AAMI/ANSI-ST8 Hospital sterilizers EN 285 Large Sterilizers.
Page 16: Symbol Descriptions
Symbol Description Symbol Description Caution! Consult accompanying documents Caution! Hot surface Caution! Hot steam Protective earth (Ground) Utility Labels Utility Specification Mineral Free Water 2–5 bar (30–70 psi) Steam 3.5–4.5 bar (60–65 psi) Tap Water 2–5 bar (30–70 psi) Compressed Air 6–8 bar (85–115 psi) Electricity 3 Ph, 208V/ 60Hz, 105 A...
Page 17: Installation
INSTALLATION Environmental Conditions Ensure all shut-off valves or switches from the building services to the autoclave, for example compressed air, electricity, steam, water, etc. are clearly marked, and are located in an easy to reach, unrestricted area. Ensure all personnel working with or around the autoclave are properly trained in the location of all the shut off valves and switches that supply services from the building to the autoclave.
Page 18 Drain  Connect the following outlets directly to the drain funnel. or connect them through a drain collector pipe of 4-6‖ that should be covered. The drain system should be vented.  General drain outlet by a ¾" pipe.  Vacuum pump by a 1"...
Page 19 Electrical Power Connection Warning! Only a qualified electrician may perform the electrical connections! The electrical units should not be placed near water sources. Connect the power cord to the electric box of the autoclave Electrical data 3 Ph, 208V/ 60Hz, 105 A Electrical cable requirements 5 X 50 mm Note:...
Page 20: Preliminary Check
Preliminary Check After installation, and prior to putting the machine into operation, the following checkout procedure is to be fulfilled:  Check the connection to local sewage. Check that the sewage pipeline is not clogged. (Pour water for this task). ...
Page 21 Performing Safety Tests  Check the tightness of all the nuts and screws.  Test the earth continuity – use a Megaohm Tester.  Check current leakage. Check Voltage and Amperage.  Adjust the legs of the transfer carriage to equal the height of loading cart to rails in the sterilization chamber.
Page 22: Functional Description
FUNCTIONAL DESCRIPTION The Steam Generator A built-in steam generator is installed to act as a standby if building steam is not available for the sterilization process. See ―Switching to Steam Generator‖ section for steam generator operation. The power consumption of the generator is 36 kW. Water to the steam generator is supplied by a one-phase pump, from a water reservoir, which is connected to a source of distilled or de-mineralized water.
Page 23: Generator Electrical Safety System
Preparation By: Description Date Rev. No 3.1.1 Electrical Safety System There is an electrical safety system to protect the heating elements if a fault condition is R/L1 S/L2 T/L3 detected by any one of the safety devices, namely: GICAR 2DRLH ...
Page 24: Gicar Water Level Controller
3.1.3 GICAR Water Level Controller The water level control system consists of three electrodes. (HIGH and LOW water level), and a reference electrode, all connected to the GICAR 2DRLHG controller. Front of Generator Dimensions in mm The long electrode which is continuously immersed in the water, acts as a reference and is connected to ground.
Page 25: Generator Electrical Layout
GENERATOR ELECTRICAL LAYOUT MAN205-0195042EN Rev. A Aug. 2011 Page 19 of 137 pages...
Page 26: Generator Electrical Diagram
GENERATOR POWER ELECTRICAL DIAGRAM Legend: 1. HEATERS = 208V /6000W 2. KM1 & 2 = CONTATOR: DILM65 33. CB1 & 2 = CIRCUIT BREAKER:FAZ-3 C63 44. QS1 = PANEL SWITCH: 3 PH 125A MAN205-0195042EN Rev. A Aug. 2011 Page 20 of 137 pages...
Page 27: Generator Control Electrical Cascade Diagram
GENERATOR CONTROL ELECTRICAL CASCADE DIAGRAM MAN205-0195042EN Rev. A Aug. 2011 Page 21 of 137 pages...
Page 28: The Piping System
The Piping System The piping system of the autoclave consists of air-operated valves, which control the condensate and steam flow in and out of the chamber, operate the vacuum, and the air inlet valve. The air pulses to the pneumatic valves are transmitted through solenoid pilot valves, operated at 24VDC.
Page 29 Vacuum to gasket valves (53 1-2) – connect the gasket grooves to the vacuum pump. When a door moves, during opening and closing, this valve is open and vacuum is produced to draw the gasket into the groove, ensuring a smooth sliding of the door. When the door is open, this valve is operated but vacuum is not produced.
Page 30: Piping System Drawing
PIPING SYSTEM DRAWING MAN205-0195042EN Rev. A Aug. 2011 Page 24 of 137 pages...
Page 31: The Pneumatic Control System
The Pneumatic Control System The pneumatic control system is built as follows (refer to drawing on the next page): The compressed air is supply at a pressure of 6-8 bars. Pressure regulator reduces the pressure to 6 bars. Air is transmitted to the inlet of the pilot solenoid valve battery, which is mounted on a manifold branch base.
Page 32: Pneumatic Control System Drawing
PNEUMATIC CONTROL SYSTEM DRAWING MAN205-0195042EN Rev. A Aug. 2011 Page 26 of 137 pages...
Page 33: Absolute Pressure Transducers
Absolute Pressure Transducers The transducer type MT 3296 is a membrane pressure sensor and electronic measuring circuit, with the following specifications:  Pressure range: 0-4bar (0–58 psia).  Output span current: 4-20mA  Supply voltage: 10V to 30V The autoclave is fitted with four pressure transducers for controlling & monitoring: Chamber pressure –...
Page 34: The Vacuum Pump And The Heat Exchanger
The Vacuum Pump and the Heat Exchanger For the generation of vacuum in the air removal and dry stages, the autoclave is equipped with a water ring seal vacuum pump – Speck V 55, suitable for continuous operation, and for achieving high vacuum. The tap water necessary for the operation of the pump is supplied by the water reservoir, connected to the tap water source.
Page 35: The Electrical System
The Electrical System The electrical system of the autoclave comprises of the power circuits including the commands, switching, and protective components required for the operation of the electrical equipment of the unit. The following parts are located in the electrical boxes, mounted on the side of the autoclave: ...
Page 36 The command circuits are energized by a power supply with two outputs, as indicated below:  5 VDC for the digital circuits.  24 VDC for the solenoid valves. The coils of the solenoid valves are 24V and are operated by the controller. The solenoid valves are activated when the control voltage output is low (less than 2V) with respect to ground.
Page 37: The Control System
The Control System The Main Board Controls and monitors the physical parameters of the process and performs the operation sequence of the machine, according to the selected program. The main board contains the following elements:  16 digital inputs  24 digital outputs ...
Page 38 Analog inputs for Reading Temperature Temperature is measured using PT100. The system contains 2 ADC components, each component being able to read 3 PT100 sensors. The system contains circuits with a direct connection of PT100 (3 wires) that do not interchange on the way. The measurement range is 25–150ºC (80–300ºF).
Page 39 Measuring steam generator pressure The measurement range is 100-600kPa (14.5–87 psi) The resolution measurement and display is 1kPa (1 psi). The accuracy of the measurement is a maximum 1% of the range, i.e. 5kPa (0.7 psi) Calibration of the pressure circuit requires a special engineer access code. 3 Serial Ports The control system contains 3 serial ports (1optional) according to the following specifications:...
Page 40: Safety Interlock Devices
SAFETY INTERLOCK DEVICES MAN205-0195042EN Rev. A Aug. 2011 Page 34 of 137 pages...
Page 41: Electrical Control System Drawing
ELECTRICAL CONTROL SYSTEM DRAWING MAN205-0195042EN Rev. A Aug. 2011 Page 35 of 137 pages...
Page 42: Water Quality
Water Quality Physical Characteristics and Maximum acceptable contaminants levels in water or steam, for steam generator and sterilizers (According to EN 285:2006). Contaminants in Contaminants in condensate at water supplied to steam inlet to generator sterilizer ≤ 10 mg/l Evaporate residue ≤...
Page 43: Control And Monitoring
CONTROL AND MONITORING Control Panel CAT 2007 MAN205-0195042EN Rev. A Aug. 2011 Page 37 of 137 pages...
Page 44: Keypad
Description of Panel CAT 2007 The Operation Panel consists of the following parts:  4 rows display, 20 characters in each row.  17 keys  2 LEDs (Fail, Run)  1 locking key 4.1.1 KeyPad STANDBY The ON/ST.BY key is located on the top right side of the panel. Press this key to light up the operation panel.
Page 45 START Key When the autoclave is in the Ready position, pressing START activates the cycle. STOP Key This key is active while the autoclave is in operation. Pressing STOP at any stage of the cycle stops the operation. Canceling the FAIL message At the end of an aborted process the FAIL light is turned ON and an error message is displayed on the screen indicating the cause of the failure.
Page 46: Display
4.1.2 Display Note: Temperature and pressure measuring units differ according to the country of operation. Temperature and pressure are displayed in both ºC or ºF and kPa or psi, respectively. The CAT2007 display consists of 4 alphanumeric rows with 20 characters in each row (see Figure below) First Row First 3 characters define the Cycle no.
Page 47 The 12 cycles, names of programs and relevant temperatures are listed below: Cycle no. Program Temp ºC 1, 2, 3 Un-wrapped 4, 5, 7 Wrapped Wrapped 8, 9, 10 Slow Exhaust B&D test — Leak test Second Row: This row displays the temperature in the chamber, pressure in the chamber, and jacket pressure.
Page 48: Description Of Displayed Messages And Safety Measures
Description of Displayed Messages and Safety Measures This message is displayed and the FAIL indicator lights up 03 - Manual Stop after the STOP key is pressed for more than 1 second during the cycle (excluding the drying stage). This message is displayed and the FAIL indicator lights up 100 - Man.
Page 49 This message indicates that during opening Door #1, you do 23 - Door1 Gasket Low not achieve the proper vacuum in Gasket1. Vacuum If whilst opening Door #2 you do not achieve the proper 24 - Door2 Gasket Low vacuum in Gasket2. Vacuum This message is a result of a safety mechanism indicating that if during the pre-vacuum stage, drying stage, vac.
Page 50: Operating The Control Panel
Operating the Control Panel 4.3.1 Starting Up the System After turning ON the system, the following screen is displayed for a few seconds: After a few seconds the Stand By screen is displayed. This is the central screen from which all operations are performed. It is also the ―Ready‖...
Page 51: Selecting A Cycle
4.3.2 Selecting a Cycle A cycle can only be selected in Stand By from the Stand By / Ready screen which displays the cycle number and name in the top row. To select a cycle: Press the UP/DN keys to change the cycle where pressing UP moves to the next program and pressing DOWN moves to the previous program.
Page 52 Running a Cycle Before starting a cycle, make sure to check the following:  Select the steam source.  If the building steam source is supplying enough steam to operate the autoclave. If not, use the internal steam generator. See ―Switching to the Steam Generator‖...
Page 53 In/Out Test – Design: The system contains a stage called In/Out Test Stage. This includes all the required elements for the In/Out Test. The test includes:  Testing all the outputs. Each output is turned ON one at a time. The output passes to ‗ON‘...
Page 54 Testing the In/Out Routine Turn ON the system. Press the OPTION key. The right command key will be called In/Out. By pressing on this key, the screen displays: Code: Enter In /Out Test Code: Enter the code 2ØØ7. The screen will display the message ‗Digital Ø1 On!!!‘ Be sure that OUTØ1 is ON. Press on ‗UP‘, the screen displays the message ‗Digital OUTØ2 ON!!!‘...
Page 55: System Setup (Changing Parameters And Values)
4.3.3 System Setup (Changing Parameters and Values) Note:  The system allows 15 seconds for values to be entered. If this time passes and the panel has not been touched, the display will automatically move to the next screen.  When codes are not entered within 15 seconds, the RUN and FAIL LEDs light and the display returns to WAIT and then to the Stand BY screen.
Page 56 Clock The clock first displays the date and then the time. Date The date is always displayed as day/month/year. Press the UP/DN keys to change the value. Press ENTER (the right command key), after selecting the desired value to move on to the next value, i.e. the 'day value' will be underlined. Press the UP/DN keys to change the value and ENTER.
Page 57 Doors Number After entering the language, the following message is displayed: This autoclave has two door, press ØØØ2. Press ENTER, and the system moves to the next screen. Door Type There are 3 different types for autoclaves – Manual Door, Automatic Hinged Door, or Automatic Sliding (horizontal or vertical) Door.
Page 58: Changing Cycle Parameters
4.3.4 Changing Cycle Parameters The screen that allows for parametric changes appears as follows: Press CLEAR or ENTER before entering the code to return to the Stand By screen; the RUN & FAIL LEDs are lit. Enter the correct code via the UP/DN keys. Press ENTER to proceed to the next screen.
Page 59 Heat T.O. – Maximum time for heating the chamber for starting sterilization When the duration of the heating stage is longer than Heat T.O., the program will stop and display the message ‗Low Heat‘. Entry code Resolution 1 minute Minimum value 20 minutes Maximum value 60 minutes...
Page 60 VacDip2 – Vacuum value in the remaining pulses This value defines the vacuum in the remaining pulses in the pre-vacuum stage (not just pulse no. 2) Entry code Resolution 1kPa (0.1 psi) Minimum value 1kPa (0.15 psia) Maximum value 75kPa (10.8 psia) VacTime1 –...
Page 61 LimitP add – Adding pressure to the maximum pressure This value defines the addition to the maximum pressure, computed to the jacket control. For example, when the desired temperature is 134ºC (273ºF) the maximum temperature maintained in the jacket will be adjusted to a temperature of 137ºC (i.e. 332kPa) - 278 ºF (48 psi) When this pressure is not enough, it can be increased by changing the values of the LimitP add.
Page 62 Select PT100 There are 2 temperature sensors that regulate cycles: (double) in the condensate line: PT100 – No. 1 Sensor 1: PT100 – No 5 Sensor 5: in the drain line This is the final parameter under Code 13. Pressing ENTER returns the display to the ST.BY screen.
Page 63: Door Display Function
4.3.5 Door Display Function (Applicable only for automatic doors) Displays when Opening or Closing the Doors Opening an Automatic Door While an automatic door is opening, the message OPENING DOOR – WAIT appears in the 3rd row. Closing an Automatic Door While an automatic door is closing, the message CLOSING DOOR –...
Page 64: Display During A Cycle
4.3.6 Display During a Cycle Display during the Pre-Vacuum Stage When the cycle passes to the Heat stage the steam enters the system, in place of ‗PUMP TO 25K‘, it will display ‗HEAT TO 160K‘. When the cycle passes to the Exhaust stage,‘ it will display ‗EXH TO 100K‘. Display during the Heating Stage Display during the Sterilization Stage Display during the Drying Stage...
Page 65: Printer
PRINTER Printer Output 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). The printing is made on plain paper with 24 characters per line and contains the following information: ...
Page 66 PRINTER OUTPUT DESCRIPTION Autoclave serial no. Autoclave 1102058 Name : __-------- Name of the operator to be filled in . Load #: 0030 30/08/2011 13:45:16 Date and time the cycle ended The time, temperature and pressure during E13: 31 099.7ºC 049.5k exhaust stage.
Page 67: Printer Handling
Printer Handling Setting Paper Press the paper cover open button, and open the paper cover. Handle the paper cutter carefully not to cut your hand. Set a paper roll as shown in the figure. Close the paper cover by pressing both ends of the cover with the tip end of the paper emerging from the cutter.
Page 68 Power OFF the printer in any of the following cases:  The printer does not recover from an error.  Smoke, strange noises or smells erupt from the printer.  A piece of metal or any liquid touches the internal parts or slot of the printer. Notes on treatment of thermal papers: ...
Page 69: Sterilization Programs
STERILIZATION PROGRAMS Program Descriptions The autoclave is equipped with 12 programmable sterilization programs and two test programs. The test programs are pre-set by the manufacturer in such a way, that their parameters are not changeable. Following are the names, relevant programs with related temperatures of the 12 sterilization cycles and 2 test programs.
Page 70 Program 1, 2, 3 for Un-wrapped goods 134ºC (process Sample) These programs are intended for un-wrapped rigid items, for example instruments and other goods, which their manufacturer declares their compliance to be sterilized in the following conditions:  Sterilization temperature 134ºC ...
Page 71 Program 4, 5, 7 for Wrapped goods 134ºC (Process Sample) These programs are intended for wrapped goods, for example instruments and other goods, which their manufacturer declares their compliance to be sterilized in the following conditions:  Sterilization temperature 134ºC ...
Page 72 Program 6 for Wrapped goods 121ºC (Process Sample) This program is intended for wrapped goods, for example instruments and other goods, which their manufacturer declares their compliance to be sterilized in the following conditions:  Sterilization temperature 121ºC  Sterilization time 15 minutes ...
Page 73 Program 8, 9, 10 – Slow Exhaust 121ºC (Process Sample) These program are intended for the sterilization of liquids which require a slow pressure exhaust which comply with their manufacturers declares their compliance to be sterilized in the following conditions: ...
Page 74 The color shall be a uniform black. If the color is not uniform black the verification should be ejected and notify your authorized Tuttnauer technical representative for service. Program: 11- Bowie & Dick Test 134°C 3.5 min 134°C/ ~305 kPa...
Page 75 At the end of the cycle, the unit printer will print "PASS" or "FAIL" on the tape printout. In the event of test failure, repeat the test. In case of repeated test failure, notify your authorized Tuttnauer technical representative. Performance Description: A vacuum is drawn in the chamber down to 18 kPa.
Page 76: Preparation Before Sterilization
PREPARATION BEFORE STERILIZATION Note: Liquids can only be sterilized in an autoclave with two temperature sensors in the chamber. Instruments to be sterilized must be clean, free from any residual matter, such as debris, blood, pads or any other material. Such substances may cause damage to the contents being sterilized and to the sterilizer.
Page 77: Loading
The following is recommended: Tubing Rinse tubing after cleaning with pyrogen free water. When placing in tray, ensure that both ends are open, without sharp bends or twists. Packs Place packs upright on trays, side by side. Packs should not touch the chamber walls. Sterilization in slow discharge of pressure Use only heat-proof glass, filled 2/3 full.
Page 78: Un-Loading
Hooks release handle Securing hooks Transfer Carriage Loading Cart Un-loading When the buzzer signals the successful completion of a cycle, open the door and let the load cool down for several minutes. Hook the transfer carriage firmly to the autoclave, apply the brakes, and roll the loading cart out of the chamber.
Page 79 Warning! During loading and unloading use safety gloves and glasses in accordance with local safety regulations and good practice. It is strictly forbidden to enter the autoclave chamber! If, for any reason (for cleaning, maintenance or if something falls down), it is necessary to enter the chamber, the person must lock the system by pressing the emergency switch and take the key with him to prevent accidents and unauthorized use.
Page 80: Operating Instructions
OPERATING INSTRUCTIONS Attention! Liquids can only be sterilized if there are two PT 100 flexible temperature sensors in the chamber. Warning! Do not operate the autoclave in the presence of dangerous gases and vapors. Observed the manufacturer recommendations sterilization data for each type of material.
Page 81: Failed Cycle
Note: When a sterilization program is running, the LED RUN lights up on the control panel. At the end of the cycle a buzzer sounds and the word "END" is displayed. Press STOP to cancel the buzzer. Open the door by pressing the F3 key while "OPEN"...
Page 82: Aborting A Cycle
SEQUENCE IS COMPLETE. IF THE CONTROLLER DOES NOT INDICATE THAT THE SEQUENCE IS COMPLETE, DO NOT ATTEMPT TO OPEN THE DOOR. CONTACT YOUR TUTTNAUER TRAINED AND CERTIFIED AUTOCLAVE TECHNICIAN. DO NOT ATTEMPT TO OPEN THE DOOR IF THE PRESSURE IS ABOVE ATMOSPHERIC PRESSURE.
Page 83: Switching To The Internal Steam Generator
Switching to the Internal Steam Generator If the building steam supply fails: Open the generator electric box, switch ON the 3 Phase circuit breaker with its Trip Coil, and ensure all the other circuit breakers are ON. Observe the generator pressure gauge is at working pressure, (4.5 bar). Turn OFF Building steam inlet and turn ON Generator inlet steam using the ON-OFF-ON switch on the front panel of the autoclave.
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Page 85: Service Instructions
SERVICE INSTRUCTIONS Warning! These service instructions are for the use of qualified personnel only! To avoid electric shocks, do not perform any servicing other than that specified in the operating instructions unless you are qualified to do so. Refer all servicing to qualified service personnel.
Page 86: Maintenance Of The Autoclave
MAINTENANCE OF AUTOCLAVE Preventive and Periodical Maintenance 1. Clean the strainer at the bottom of the chamber. 2. Verify that the door gasket and the surface that the Before each cycle gasket is pressed on are clean. 3. Keep the door closed between sterilizing cycles. 1.
Page 87 Before start of day/shift after the weekend, re-place the door gasket according to the instructions in the ―Replacing the Door Gasket― section. For Tuttnauer internal steam generators. 1. Press the Test Button on the internal steam generator electric box.
Page 88 1. Perform an overall check of the locking system and replace worn parts. 2. Check and tighten where necessary the electrical connections in the electrical board, connection box, motors, electrical valves, locking device screws and instrumentation. 3. Clean the electronic control unit, using a vacuum cleaner.
Page 89 Notes: The procedures done by the ―User‖ referred in the Preventive and Periodical Maintenance, must be performed by trained personnel only. Keeping the inside of the autoclave clean will lengthen its life and its proper operation. Ensure the chamber is empty and cold during all cleaning. For all cleaning use ordinary household stainless cleaner, and rinse first with tap water, and then with distilled or mineral free water.
Page 90: Safety Tests After Repair
Safety Tests after Repair Attention! After every repair or dismantling the enclosure, the autoclave should pass two electrical safety test by the qualified Service Engineer. The following shall be performed: Enclosure Leakage Current Test. Every autoclave should pass this test as follows: Connect the electrical cord to the autoclave.
Page 91: General Troubleshooting
General Troubleshooting Possible causes check-ups Symptoms Corrections and tests 1. Control unit not initialize. The control circuit Check and switch on No display and lights on the breaker switched off. the circuit breaker. front panel. The power switches Replace the defective on the front panels of switch.
Page 92 Possible causes check-ups and Symptoms Corrections tests 3. Steam pressure Pressure switch faulty or Check, repair or increases beyond the incorrectly set. replace the control point. pressure switch. Contacts at contactor Check the cause welded because of short and replace the circuit.
Page 93 Possible causes check-ups and Symptoms Corrections tests 6. Temperature rises Steam pressure too high. Check and set above the preset correctly the sterilization value. pressure switch of the generator and the pressure reducer. Steam valve leaks. Fix or replace the steam valve.
Page 94 Possible causes check-ups and Symptoms Corrections tests 12. The door does not 12.1 Low pressure at the air 12.1 Set the air close. supply line. pressure; 1.5 bar (Applicable to sliding 12.2 CLOSE DOOR solenoid 12.2 Fix or replace doors) valve transmitting air solenoid valve.
Page 95 Possible causes check-ups and Symptoms Corrections tests 15. Problems related to 15.1 Check if the flat cable or 15.1 Plug in firmly the the control system. MOLEX connectors MOLEX between the control boards connectors. and keyboard are well plugged in. 15.2 Power supplies out of order.
Page 96: Steam Generator Troubleshooting
Steam Generator Troubleshooting Symptom Possible cause Corrections 1. Steam 1.1 No power from the building 1.1 Check the reason for no generator does source. power supply from the not start. building. 1.2 Generator Circuit breakers 1.2 Turn ON the circuit (1ph &...
Page 97 Possible cause Corrections Symptom 3. Steam pressure 3.1 The pressure switch is faulty 3.1 Check the pressure does not or incorrectly set. switch, set it correctly or increase or replace if faulty. increases too 3.2 The circuit breakers in the 3.2 Check the cause and slowly.
Page 98: Troubleshooting For Water Pump Shurflo
Troubleshooting for Water Pump SHURFLO Symptom Possible cause Corrections 1. Pump does not 1.1 Fuse burnt or circuit 1.1 Replace fuse or turn start. breaker tripped. on the circuit breaker. 1.2 Wrong voltage. 1.2 Use right voltage. 1.3 Damaged electrical connection.
Page 99: The Shurflo Water Pump Rear Endbell Replacement Kit
The windings should not be overheated, black in color, or have a burnt odor. If the motor has any indication of the aforementioned or other failure modes, the endbell kit will not correct the failed condition. Complete motor assemblies. Contact Tuttnauer for a complete motor assembly. Replacement Instructions: Mark the motor housing to index the location of endbell wires to the housing.
Page 100 Slide the new endbell assembly onto the shaft as far as the brush retention clip will permit. Index the endbell wires to mark made in step #1. Align endbell to the slots in the motor housing. Pull the brush retaining clip out while pressing the endbell flushes to the motor housing.
Page 101: Generator Maintenance
Generator Maintenance 9.7.1 Generator Pressure Switches The generator is equipped with two pressure switches: Operating Control Pressure Switch -This switch sets the nominal working pressure and the upper and lower pressure in which the generator turns ON and OFF. Limit Control Pressure Switch -This switch sets the cut-off pressure of the generator.
Page 102: Cleaning And Replacing The Water Level Electrodes
9.7.2 Cleaning and Replacing the Water Level Electrodes The three electrodes of the water level control system are located on top of a tank mounted on the side of the steam generator. Cleaning the Water Level Electrodes Turn OFF the electric power and discharge the steam pressure from the autoclave and the steam generator.
Page 103 Replacing the Water Level Electrodes Turn OFF the electric power and discharge the steam pressure from the autoclave and the steam generator. Disconnect the wire from the electrode connections. Note: Mark the wires before removing them. It is essential to return the correct wire to the correct electrode! Remove the electrode.
Page 104: Replacing The Heaters
9.7.3 Replacing the Heaters Disconnect the steam generator from the electrical source. Release the steam pressure from the autoclave and the steam generator. Flush the water out of the steam generator then close the drain valve. Remove the heaters cover. Remove the wire connections from the heaters.
Page 105: Replacing The Generator Side Gauge Glass Indicator Tube
9.7.4 Replacing the Generator Side Gauge Glass Indicator Tube Note: On each side of the glass tube, there are stainless steel balls that act as a safety device by preventing the escape of steam and boiling water if the glass is broken.
Page 106: Releasing The Vacuum Pump Rotor
Releasing the Vacuum Pump Rotor The vacuum pump could get locked after a prolonged idle period. Further described, is the procedure to follow in order to unlock and restore the normal operation of the pump. When the pump is operated for the first time, check if it works normally. If not, stop the electric current immediately.
Page 107: Test Points - Cat 2007
Test Points – Cat 2007 NUT TP FUNCTION Analog Input N 13 (Door 1 Press.) Analog Input N1 (Cond. Temp.) Analog Input N14 (Door2 Press.) Analog Input N 2 (Cond. Temp.2) Analog Input N 15 Analog Input N 3 (Temp.) Analog Input N 16 Analog Input N 4 (h-electrode) TP11...
Page 108: Calibration
9.10 Calibration The programming of the calibration procedure is almost identical for both temperature and pressure. Calibration is performed digitally. The temperature and pressure measuring circuits are designed with components having a 1% precision. The temperature circuit is linear and has an output of 100mV-2400mV for a temperature range of 20ºC-150ºC (68ºF-302ºF).
Page 109: 9.10.1 Calibrating Temperature And Pressure
9.10.1 Calibrating Temperature and Pressure Return to the ST.BY screen and select the OPTION command key. The word CALIB is displayed above the middle command key. Press the middle key and the same screen for entering the SETUP code will appear. Enter the correct code via the digital key;...
Page 110 Temp 2: Temperature of sensor 2. Refer to Temp1 for instructions. Temp 3 (Option): Temperature of sensor 1. Refer to Temp1 for instructions. Temp 4 (Option): Temperature of sensor 2. Refer to Temp1 for instructions. Temp 5 (Drain) Temperature of sensor 5 Refer to Temp1 for instructions.
Page 111: 9.10.2 An Example Of Temperature Calibration
When checking chamber TC for 121ºC (250 F) it shows 121ºC (250 F) The temp for 134ºC (273 F) needs correction without changing the accurate Temp of 121ºC (250ºF) The data should be set as follows: Upper Row A 121 (250) R 121 (250) A 132 (270) R 134 (273)
Page 112: Working With Power On In Service Area (Autoclaves With Sliding Doors)
9.11 Working with power ON in Service Area (Autoclaves with sliding doors) Warning! It is strictly forbidden to enter the service area! If maintenance is necessary behind any service access panel(s) while the system is operating, proceed as follows: Ensure the chamber door(s) are closed. Lock the system by pressing the emergency switch to turn OFF all electrical power to the autoclave and withdraw the key.
Page 113: Testing The Safety Valves
9.12 Testing the Safety Valves Warning! Before testing the safety valve, wear heat resistant safety gloves and keep all body parts away from the steam flow. Attention! Make sure that the test is performed while the door is closed. 1. Testing the Generator Safety Valve Ensure the autoclave green toggle switch is OFF.
Page 114 If the safety valve did not blow at the pre-set pressure stop the operation of the autoclave, decrease the pressure to atmospheric pressure and replace the safety valve with a new one. If the safety valve was replaced, repeat step 2.1—2.5 to test the new one. Close solenoid valve 91 (screw's slot is horizontal).
Page 115: Replacing The Door Gasket
9.13 Replacing the Door Gasket Warning! Before replacing the gasket, verify that the autoclave is cold; that the power is turned OFF; and, that there is no pressure in the jacket and in the chamber. Remove the damaged gasket. Check the new gasket and verify that it is not damaged. Verify that the gasket groove is clean.
Page 116: Servicing The Vertical Door Operation Cylinder
9.14 Servicing the Vertical Door Operation Cylinder The cylinder is a hydro-pneumatic unit, consisting of a pneumatic power section and a hydraulic control section. The hydraulic control section consists of hydraulic oil. Checking Oil Quantity When the door is fully open (the operating piston is completely inside the cylinder), check if the reference notch on the oil tank stick gauge (1) is visible.
Page 117: Spare Parts
SPARE PARTS LIST Part No. Description ARM029-0006 Pressure Reducer, Steam, RE1, ½", Miyawaki ARM029-0007 Pressure Reducer, Steam, RE1, ¾", Miyawaki  ARM100-0053 Heat Exchanger,1", 15ORZ2, Oran ARM100-0057 Steam Trap, ¼", St.St., MST21, NPT, Spirax-Sarco ARM100-0069 Steam Trap, ½", without bypass,N125W, Nicholson ARM100-0070 Steam Trap, ½", with bypass, N125WSLR, Nicholson ARM100-0140...
Page 118 Part No. Description Electronic Level Regulator, one electrode, 115V, DRL H  CTP201-0230 S, Gicar  CTP201-0271 Relay Socket, 95.65 SM A, Finder Miniature PCB relay, coil 24VDC, contact 250VAC, 8A, 2  CTP201-0272 pole, 40.52.7.024.0000, Finder R ELE034-0017 Circuit Breaker, 1 pole, 4A, FAZ-C4, Moeller ...
Page 119 Part No. Description  FIL175-0605 Strainer, ¾" , St.St, Y Type, VS01, Victory valves  FIL175-0607 Strainer, 1" , St.St, Y Type, VS01, Victory valves GAS081-0015 Gasket, Door, Inflatable, 21mm, 26"x28", 2830mm GAS082-0005 Gasket, Glass Tube GAU029-0002 Gauge, Pressure, Steam, 0-90 psi, 2.5" GAU029-0003 Gauge, Pressure, Steam, 0-60 psi, 2.5"...
Page 120 Part No. Description Valve, Solenoid, 2/2 way, ¼"NPTx1.6, N.C., GEM-A- SOL026-0001 22113, Bac. SRV000-0125 Tube, Glass, Water Level, generator, 220 TYPE Safety Valve, ASME, ¾" MPT x 1' FPT, Brass Body, SVL029-0033 Brass Seat, 75 PSI, Open Lever Safety Valve, ASME UV/PED, ½" MPT x ¾" FPT, Brass SVL029-0074 Body, Brass Seat, 2.8 Bar (40 PSI), Open Lever "...
Page 121 Part No. Description  VLV170-0055 Valve, Manual, Ball, Mini, ¼", Sistem Pneumatica Valve, Air-Air Operated, Ball, ½"NPT, St.St. T-  VLV170-0077 PAV911.DA, Tork Valve, Pressure-Spring Operated, Angle Body, NC,  VLV170-0150 ½"NPT, St.St., 8290A792-VI, ASCO Valve, Pressure-Spring Operated, Angle Body, NC, ¾" ...
Page 122: 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 Tuttnauer. Change-over : steam / electricity Locking door cylinder (front door) Locking door cylinder (Rear door) Feed water –...
Page 123 Vacuum - break Vacuum - to pump VACUUM 53-1. Vacuum - from door 1 seal 53-2. Vacuum - from door 2 seal Vacuum Test N.C. Drain – from reservoir Drain – from jacket overflow Drain – from vacuum pump / ejector Drain –...
Page 124: Pressure Vs Temperature For Saturated Steam
PRESSURE Vs TEMPERATURE FOR SATURATED STEAM psia InHg °F °C psia psig °F °C 2.95 114.5 45.8 17.1 219.7 117.9 104.3 4.44 129.3 54.1 17.2 219.9 118.6 104.4 5.90 140.2 60.1 17.2 220.1 118.6 104.5 7.39 149.1 65.0 17.3 220.3 119.3 104.6 8.86...
Page 125 psia Psig °F °C psia psig °F °C 20.5 229.3 141.3 109.6 24.6 239.2 169.6 115.1 20.6 229.5 142.0 109.7 24.7 10.0 239.4 170.3 115.2 20.6 229.6 142.0 109.8 24.7 10.0 239.5 170.3 115.3 20.7 229.8 142.7 109.9 24.8 10.1 239.7 171.0 115.4...
Page 126 psia Psig °F °C psia psig °F °C 29.4 14.7 249.1 202.7 120.6 34.6 19.9 258.6 238.7 125.9 29.5 14.8 249.3 203.4 120.7 34.7 20.0 258.8 239.4 126.0 29.5 14.8 249.4 203.4 120.8 34.8 20.1 259.0 240.2 126.1 29.6 14.9 249.6 204.1 120.9...
Page 127 psia Psig °F °C psia psig °F °C 45.8 31.1 275.2 315.8 135.1 40.6 25.9 268.2 280.0 131.2 45.9 31.2 275.4 316.5 135.2 40.7 26.0 268.3 280.8 131.3 46.0 31.3 275.5 317.2 135.3 40.9 26.2 268.5 281.7 131.4 46.2 31.5 275.7 318.5 135.4...
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Page 129: Xpcs Manual
XPCS MANUAL MAN205-0195042EN Rev. A Aug. 2011 Page 123 of 137 pages...
Page 130 Definitions PC – Personal Computer Program – a complete, self-contained set of computer instructions that you use to perform a specific task such as word processing, accounting or data management. Program is also called Application. PCS – Cat Technologies LTD. code development, controlling and communication technology.
Page 131 User Requirements To operate this program the user needs a basic knowledge of PCS. Installation Select the CD drive by double-clicking on it. When the window opens find and double-click on the file "setup.exe" This will launch the installer, follow the on-screen instructions. Using XPCS Configuring the Program On 'XPCS' main window, press the 'Options' button;...
Page 132 Modem Configurations To connect to the remote target via a modem, select 'Active' check box in 'Modem Config' frame. 'Connection Timeout' is the waiting time in seconds to request data from the PCS target platform. If no data is retrieved from the target after the waiting time, the program generates a communication time error.
Page 133 Connecting to the PCS Target platform The program can be connected to the PCS Target by a RS232 serial cable, or via a modem. If the program is configured to perform a connection via a modem (Modem Active selected), pressing the 'Go Online' button on the main XPCS window will display the 'Modem connection' dialog box: By pressing the 'Connect' button, the program will try to connect to the remote PCS Target.
Page 134 Pressing the 'Go Offline' button will close the current connection and buttons 'Go Online', 'Options' and 'Database' will be displayed on the main XPCS window: Pressing the 'Calibration' button will display the 'Calibration' window. Pressing the 'Download' button will display 'Download' window. Calibration Window The calibration window will try to connect with the PCS Target platform.
Page 135 Type File Button This button enables the user to select a target type file (e.g. in the calibration window below, the file is: "C:\pcs\dbase\LabTn2.DWN"). Pressing this button will display 'Open file' dialog box. If the program will find a file with the same name in ADMC directory, in the Inputs table, the Analog inputs names will be displayed in color.
Page 136 Download button – Press this button to download Gain and Offset of the current selected analog input. The values displayed in Gain and Offset text boxes will be downloaded. If inserted values are wrong, a relevant error message will be displayed and the download operation will be aborted.
Page 137 Status bar The status bar at the bottom of the window displays the current downloading process status. (In the example above: "Ready to process"). Download button Press this button to perform the downloading of the selected file. While performing downloading, the program will display downloading process progress messages. After the downloading process is complete, the status bar will display "Download Finished".
Page 138 If 'Get and Set Gain & Offset' option in 'Options' window is selected, the program will download values of all analog inputs gain and offset. The message: "Downloading Gain and Offset..." will be displayed on the status bar. When download process is completed, the message "Download Finished"...
Page 139 Expectable Errors List Cannot Upload Gain and Offset! Description: This message may be displayed during download process, when the program is trying to upload Gain and Offset values. Reason: Probably a communication failure between PCS Target and the PC. Tips: Check if the RS232 communication cable is connected. If it is a modem connection, check if the modem cable is connected, in this case it can be that the remote modem cable is disconnected or the RS232 cable between the remote modem and target platform is disconnected.
Page 140 Fail Downloading Gain and Offset! Description: This message may be displayed during download process, when the program is trying to download Gain and Offset values. Reason: Probably a communication failure between PCS Target and the PC, or the PCS target platform is damaged and cannot save data on flash memory. Tips: 1.
Page 141 Read High must be equal or great than Read Low! Description: This message is displayed when the user is trying to calculate Gain and Offset by pressing the 'Calculate' button in the 'Calibration' window. Reason: Read High value is less than Read Low value Tips: Read High value must be greater than Read Low value.
Page 142 Illegal Baudrate: … Description: This message is displayed when the user presses the 'OK' button in the 'Options' window. Reason: Wrong Baud rate is inserted. Tips: Type values 9600 or 19200 in the 'Baudrate' text box. Illegal Wait Loop value: … Description: This message is displayed when the user presses the 'OK' button in the 'Options' window.
Page 143: Modem Connection
MODEM CONNECTION Make sure, that the downloading program includes the Modem Auto answer command determination. (Main>>Startup>>First Row) Auto Answer Command Connect RS232 to Modem Converter according the following diagram: V90/56K MODEM Comunication Port To the Autoclave Comunication Port Modem Telephone Connection To the phone Line Socket...

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