Page 1 Technician Manual Electronic Laboratory Autoclaves Models 5050 and 5075 EL- MD/EL-D EL-MD: standard autoclave (manual door) EL-D: standard autoclave (automatic door) C: optional system for fast cooling PV: optional vacuum pump BH: optional bio hazard filtration F: optional fan for super-fast cooling Cat.
Page 2: Table Of Contents
Environment Emission Information ..................11 Directives and Standards ...................... 12 Water Quality ......................... 13 4.10 Electrical Data ........................14 4.11 Overall Dimensions Models 5050, 5075 EL ................. 15 4.12 Dimensions ..........................16 4.13 Specifications ........................17 4.14 Front View ..........................18 4.15...
Page 3 8.11 Cycle parameters ........................68 8.12 Temperature sensors ......................70 8.13 Displayed inputs ........................70 8.14 Purge (generator models only) ..................... 71 8.15 Create Pulse ........................... 72 8.16 Keep Heat ..........................73 8.17 Heating ........................... 75 8.18 Sterilization ..........................75 Cooling (“C”...
Page 4 PIPING DRAWING – MODEL 5050, 5075 ELCPV(F)-MD (380/400V) ......... 148 14.3 PIPING DRAWING – MODEL 5050-5075 ELCBH D ............149 14.4 PIPING DRAWING – MODEL 5050- 5075 EL-BH (F) D ............150 14.5 ELECTRICAL WIRING DIAGRAM – MODEL 5050/5075 EL(C)(PV)(BH)(F) (230V) ... 151 14.6 ELECTRICAL WIRING DIAGRAM –...
Page 5: Introduction
1. Introduction This manual, together with the operator’s manual, forms the complete edition of the Operation and Maintenance instructions. This manual is intended for the use of the technician. It is forbidden for unqualified and unauthorized personnel to service the autoclave in accordance with the instructions in this manual.
Page 6: Stickers Description
Displayed = 10 sec. Do not Touch LAB048-0462 On the door frame Microswitches behind the door please Contact cover Tuttnauer Service Do not Touch LAB048-0463 On the door frame Microswitches behind the door please Contact cover Tuttnauer Service...
Page 7: Installation Instructions
3. Installation Instructions The following utilities must be connected (Refer to the drawing below ‘Rear View’ of the autoclave).  Power outlet, as detailed in the table below: Property Value Power 3 Ph, 400V/50/60Hz Recommended Circuit Breaker  If the 3-phase autoclave must be connected to a one phase power network, 1 x 230V, 50/60Hz., connect the 1ph 230V power source to the supplied switch box that has a 1 phase input (from the power source) and a 3-phase output (to the autoclave).
Page 8: Moving The Autoclave
Attention: Connection of water system to the autoclave must be performed through "BACK FLOW PREVENTION SYSTEM" installation as per EN 1717. Moving the Autoclave Disconnect the power supply cord. Disconnect the water and drain hoses. Disconnect the compressed air hoses (if applicable). Drain the water from the chamber.
Page 9: Technical Data
4. Technical Data Introduction Models 5050 and 5075 ELPV-D/ELCPV-D are table-top sterilizers designed especially for the sterilization of instruments, liquids, medical waste, 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 10: Stand - By Heating Mode
The autoclave is provided with a pressure gauge that is used as guide only. Should there be a power failure during the operation of the autoclave, the pressure gauge indicates to the operator that there is pressure in the chamber. A deviation of +1.6% is accepted.
Page 11: Utilities
3 Ph, 5075 6 x 1100W IEC 61010-1 400V/50Hz 3 Ph, 5050 4 x 1100W IEC 61010-1 400V/50Hz Attention: The electrical net must be protected with a current leakage safety relay. The electrical network must comply with local rules or regulations.
Page 12: Construction
Model 5050 5075 Weight 285 kg 310 kg Construction The main parts of the autoclave are made of materials as indicated below:  Chamber and door are made of stainless steel.  Trays are made of stainless steel.  Water reservoirs are made of stainless steel.
Page 13: Directives And Standards
Directives and Standards Every autoclave meets the provisions of the following Directives and is in compliance with the following Standards: ISO 9001: Quality Management System ISO 14001: Environmental Management System ISO 17025: General requirements for the competence of testing and calibration autoclaves ASME Code Section I and section VIII.
Page 14: Water Quality
Water Quality The distilled or mineral-free water supply shall be according to the table below: Suggested maximum limits of contaminants in water for steam sterilization per EN13060 Substance Feed Water Condensate ≤ 10 mg/l ≤ 1.0 mg/l Evaporate residue ≤ 1 mg/l ≤...
Page 15: Electrical Data
RO maintenance requirements are less demanding than those of the DI units. Therefore, the use of mineral free water will contribute to better performance and longer life of the autoclave. 4.10 Electrical Data 230V configuration Property Value: 5050 Value: 5075 4400W 6600W Total Power (4*1100W) (6*1100W) Voltage...
Page 16: Overall Dimensions Models 5050, 5075 El
400V configuration Property Value: 5050 Value: 5075 4400W 6600W Total Power (4*1100W) (6*1100W) Voltage 3Ph, 400VAC 3Ph, 400VAC Amperage Protection against electrical IEC 61010-1 shock Mains supply fluctuation +/- 10% 4.11 Overall Dimensions Models 5050, 5075 EL 5075 Page 15...
Page 17: Dimensions
5050 4.12 Dimensions Model 5050 5075 Dimensions 33.9 33.9 Overall Dimensions 29.1 29.1 34.3 1100 43.3 1460 57.5 1690 66.5 Maximum dimensions (door open) 37.0 37.0 25.4 25.4 Distance between supporting legs Page 16...
Page 18: Specifications
2.76 bar (40 psi) (MAWP) Load No. counter Counting from 0 to 3000 and nullifies. 4.13 Specifications Properties Model 5050 ELC 5075 ELC Chamber diameter in Chamber depth in mm 110 lit. (29.1 US 160 lit. (42.3 US Chamber volume gal) gal) Max.
Page 19: Front View
4.14 Front View No. Description No. Description Autoclave cover Safety valve Validation port (under door cover) Water reservoir cover Water reservoir – assembly Pressure gauge Reservoir water drain valve Control panel display (under door cover) Ring for drain valve (under door Control panel keyboard cover) Printer Cover...
Page 20: Rear View
4.15 Rear View Description Cut off Circuit breaker Electricity Strainer Drain Tap Water Air Inlet Page 19...
Page 21: Control Panel
5. Control Panel Control Panel Drawing Description Display Keypad: Up Button Keypad: Start/Stop Button Keypad: Down Button Printer Page 20...
Page 22: Description And Functions Of The Front Panel Keyboard
Description and Functions of the Front Panel Keyboard The front panel is composed of 3 sections: Display screen. Keypad. Printer Display screen The display is an LCD panel used to display the current status of the autoclave while using Operational Messages and Error Messages. •...
Page 23 • In the directories available: When the cursor is blinking on a number, the UP ▲ key increases its value. When the cursor is blinking on a menu selection, the UP ▲ key allows browsing backward through the menu. When adjusting a parameter and the cursor is blinking on “SET”...
Page 24: Tests
6. Tests Installation Tests The service technician shall perform the following preliminary checks before operating the autoclave: Integrity Check Perform a visual check to verify that there are no dents, scratches, broken gauges, etc. Leveling Check Check that the autoclave is leveled. Leakage current test Check the precise operation of the earth leakage relay.
Page 25: Safety Features
Perform validation of the autoclave. Check the precise operation of the earth leakage relay. Check that the autoclave is leveled. Check the safety elements; safety valve, safety and thermostats door locking mechanisms. Run basic programs of the autoclave and check the operation sequences, the sterilization parameters etc.
Page 26: Description Of The Control System
7. Description of the Control System. Block Diagram of Hardware Control System Components Main board CPU +memory- Backup power input 24/12 I/O Board 24/12 MCIMX27LVOP4A+MC13783VK5 CPU- STM32F103R6T6 Input R.T.C (including Battery) M41T81SM6E Input -24 Digital Outputs Memory card expansion -2 Analog outputs COM1 MT46H32M16LFBF- (RS232)
Page 27: Description Of The Programmable Component
Mapping of the software to the hardware – see 7.5 The Hardware architecture is based on Freescale i.MX27 PDK Evaluation Board. Description of the programmable component: Interfaces to users ⎯ Keypad: The keypad has three push buttons: Down key Up key Start/stop key ⎯...
Page 28 Digital inputs Digital Inputs Door closed J12/1 Door unlocked J12/6 Door locked J12/8 Digital outputs Digital Outputs Buzzer J13/2 Chamber heat J13/6 Water pump valve J13/10 Vacuum pump J13/12 Atmospheric air valve J14/2 Compressed air to chamber J14/4 Slow exhaust J14/6 Fast exhaust J14/8...
Page 29: Hardware Control System Components
Hardware control system components: The hardware is consisted of cards: MAIN and IO 7.5.1 Main card Ethernet Connector Connector to Power Supply Lithium coin Connector Not in use to Keypad IO Board Connector battery T.H (DC) Horizontal 3V 48mAh Connector to LCD Connector to printer Connector display...
Page 30 Development tools (MAIN card) The software develop environment is on Microsoft Visual Studio 2005 that includes the Microsoft Platform Builder for Windows CE 6.0. The specific Tuttnauer system application is written in C Sharp.net on Microsoft Compact Framework.net Page 29...
Page 31 7.5.2 IO Card Analog inputs Connection to Digital Analog Analog inputs Analog inputs MAIN Board electrodes outputs outputs Pressure (4 20mA) (PT-100) Digital inputs IO card is an independent card. It checks the card by a method of a continuous scan of all the ports, saving the data in the memory and transporting this data according to the request in the communication channel RS-232 to the personally adapted protocol.
Page 32 request is checked and if the request is legitimate, it will be taken care The IO card is controlled by the MAIN card. Only when requests are received from the MAIN, the requests will be checked and performed. The IO card will perform an electrical restart of the systems (IO card) if it does not receive requests within 5 seconds.
Page 33 01 - Read – command to IO send all the information of digital analog inputs. 02 - Write – Command to IO to activate analog and digital outputs. 03 - Read version – IO software version to verify the version. 04 –...
Page 34: Checking And Changing Parameters And Other Data
8. Checking and Changing Parameters and Other Data Bacsoft control panel allows changing parameters of the cycle and of the system, exporting various data to, and importing from, a USB device or to the printer, and some other options. Cycle parameters are changeable for Custom programs only (see Duplicate cycles), except for the Temperature sensors, Displayed inputs, and Dry Time.
Page 35: Changing A Parameter
Note: To exit every screen and to return to the previous screen (to get one level up): • Move the cursor to Exit by pressing the UP or DOWN keys and then press the Start/Stop key. - or- • Press the UP and DOWN keys simultaneously. In the next chapter you will see how to change the required parameter as desired.
Page 36 Note: Please note the maximum and minimum values for this parameter shown on the screen. Your value must be within these boundaries. Below is the example of changing the Dry time parameter on the screen used in the previous section: Page 35...
Page 37: Quick Options Screen
Note: To exit every screen and to return to the previous screen: • Move the cursor to Exit by pressing the UP or DOWN keys and then press the Start/Stop key - or- • Press the UP and DOWN keys simultaneously. Quick options screen When the autoclave is on and no cycle is running, press Up and Down keys simultaneously to enter the Quick options screen.
Page 38 Below you can find instructions how to login and enter the Main menu. Section 8.1 above explains how to browse through the menus; section 8.2 explains how to change a parameter. Below is the explanation of the Quick Options. Export to USB This subdirectory allows you to export settings and cycles history to the USB device.
Page 39 Press the Start/Stop key. The following screen will appear: To export cycles history: Choose All cycles history, 10 Cycles, or 50 Cycles. Press the Start/Stop key. The following screen will appear: Remove the USB device from the USB Socket. Print cycles This subdirectory allows printing out cycle reports for a number of previous cycles (See the Printer handling section of the Operation and Maintenance Manual).
Page 40 Choose Print last cycle, print the last 5 cycles, or print the last 10 cycles. Press the Start/Stop key. The cycle reports will be printed. Version Information This directory allows viewing information of the current, factory default, and previous software versions. Enter the Version information screen.
Page 41 Start cycle by clock This subdirectory enables the operator to start the cycle at the time set by this parameter. Enter the Start cycle by clock screen. The following screen will appear: On the Start cycle by clock screen, the time is displayed in the form “HH:MM”.
Page 42 Exit the Enabling the Start Cycle by Clock. The start cycle by clock icon appears on the display: Disabling the START CYCLE BY CLOCK On the Start Cycle by Clock screen, move the cursor to Disabled. Press Up or Down key to disable Starting cycle by clock. Exit the Enabling the Start Cycle by Clock.
Page 43: Logging In And Entering The Main Menu
On the Set date and time screen, the time is displayed in the upper row in the form "HH:MM: SS". The hour range is 24 hours (i.e. from "0" to "24"). The date is displayed in the lower row in the form "DD: MMM: YYYY".
Page 44 When the autoclave is on and no cycle is running, press the up and down keys simultaneously to enter the Quick Options screen (see 8.3). On this screen you can either proceed to login (see below) or choose one of the quick options available without login. To login as technician: On the Quick Options screen, choose login.
Page 45: Directories And Subdirectories
• Set the code to 0321. You will get to the Main menu. Below is the list and the explanation of the options available on the Main Menu. Directories and subdirectories Bacsoft control panel provides an interface that consists of control screens available through an easy scrollable menu tree.
Page 46 Directory Subdirectory Sterilization Cooling (“C” models only) Exhaust Drying Ending Global Print Rate All Print Rate Sterilization Screen Saver Pressure calibration high System Parameters Pressure calibration low Temperature calibration high Temperature calibration low Cycle Print Gap View digital inputs state View digital outputs state Test digital outputs Inputs/Outputs...
Page 47: System Parameters
Directory Subdirectory Delete custom cycles Set external IP address Import application from USB Import all settings from USB device Version Handling Import application and setting from USB Return to factory default settings The following chapter explains meaning and usage of the control screens. Below is the typical parameter changing screen: System Parameters This menu is listing the system parameters that are the same for all...
Page 48 Below is the instruction for changing the system parameters. Print Rate All In this menu you can define the time interval for printing out the cycle status, for all the stages except sterilization: The default is 3 minutes. See the Printer handling section of the Operation and Maintenance Manual.
Page 49 Pressure calibration high In this menu you can define the high calibration point for pressure. Browse to the following folder: System parameters\Pressure calibration high Change the parameter as desired. Pressure calibration low In this menu you can define the low calibration point for pressure. Browse to the following folder: System parameters\Pressure calibration low Change the parameter as desired.
Page 50: Inputs/Outputs
Inputs/Outputs It is important for the technician to control the system down to the level of specific inputs and outputs. Viewing the outputs state at specific stages of the cycle helps you diagnose the malfunctions. You can also test and calibrate inputs and outputs. Below is the typical screen for viewing/testing the inputs/outputs.
Page 51 Browse to the following folder: Inputs/Outputs\Test digital outputs Note: on the screen that appears, scroll down for more outputs. Check the checkboxes of the outputs you want to test. View analog inputs state In this menu you can view, at any stage, the values of the analog inputs at the moment.
Page 52 See below description of each option. Auto calibrate Bacsoft software has an option for automatic calibration using the PT100 simulator. On the calibration options screen, choose Auto calibrate. The following screen will appear: Calibrate analog input This menu allows calibrating analog inputs manually. On the calibration options screen, choose Calibrate analog input.
Page 53 In the Actual field, change the high and low values of the input as desired. Set gain and offset On the calibration options screen, choose Set gain and offset. The following screen will appear: Change gain and offset as desired. Restore last calibration There is an option to restore the gain and offset values set at previous calibration.
Page 54 The following screen will appear: Using the up and down keys, move your cursor to confirm and press Start/Stop. The following screen will appear: Restore default calibration There is an option to restore the default (factory) gain and offset values. On the calibration options screen, choose Restore last calibration.
Page 55: Maintenance
Using the up and down keys, move your cursor to confirm and press Start/Stop. The following screen will appear: Maintenance Maintenance procedures provided by Bacsoft software allow you additional tests and USB input/output options. Browse to the following folder: Main menu\Maintenance You will see the following screen listing the maintenance options: Page 54...
Page 56 Below is the instruction for autoclave’s maintenance menu. Export gain offset to USB In this menu you can export to USB the gain and offset you have got as a result of calibration. Browse to the following folder: Maintenance\ Export gain offset to USB Import gain and offset from USB In this menu you can import from the USB the gain and offset documents you have got as a result of calibration to the autoclave.
Page 57 Reset atmospheric pressure In this menu you can reset the atmospheric pressure value. To do so: Browse to the following folder: Maintenance\Reset atmospheric pressure The following screen will appear: Leave the door open for 2 minutes at least. Ambient temperature should be less than 45°C.
Page 58 Browse to the following folder: Maintenance\Test RTC The following screen will appear: Set the time interval as desired. Then move the cursor to start and press Start/Stop. At the end of the test, the following screen will appear: Using the Up and Down keys, move the cursor to Exit. Printer test In this menu you can check the normal function of the printer.
Page 59 See the printout shown in the Printer handling chapter of the user manual. Print all gain and offset In this menu you can print all the gain and offset for all the pressures and temperatures in the autoclave (Chamber Temperature, Chamber Pressure, Chamber Water Level, Mineral Free Water Level.
Page 60: Advanced Options
Chamber Water Level G:001.0000;O:000.0000 Mineral Free Water Level G:001.0000;O:000.0000 Advanced Options Advanced options menu gives you even more possibilities, including interface customization, changing the settings, enabling, adding, and deleting cycles, etc. Browse to the following folder: Main menu\Advanced options You will see the following screen listing the Advanced options: Below is the instruction for the Advanced options menu.
Page 61 Move cursor to the cycles you want to enable/disable and check/uncheck them as desired. Set Language In this menu you can choose the language for all the interface screens: menus, cycle information, system messages. Browse to the following folder: Advanced Options\Set Language Note: There are more languages than you see on the screen above.
Page 62 The machine will restart, and the main screen (current cycle) will appear in the chosen language. Set temperature units In this menu you can set the temperature units (Celsius or Fahrenheit) for screens and printouts. Browse to the following folder: Advanced Options\Set temperature units Change the parameter as desired.
Page 63 Set pressure units In this menu you can set the pressure units (kPa, Psia, Psig, BarA, BarG) for screens and printouts. Browse to the following folder: Advanced Options\Set pressure units Change the parameter as desired. Duplicate cycles In this menu you can create a copy of one of the cycles with all its parameters (the parameters can be changed then).
Page 64 Give the name to your cycle. Exit the menus until you get to the main screen. Select your newly created program. Note: you can select the program only when the autoclave door is open. Login again as Technician (see 8.4). In the main menu, select Cycle parameters and enter the Cycle Parameters screen.
Page 65 Now you can alter the cycle parameters as desired. Delete custom cycles In this menu you can delete the custom cycles that were created. Browse to the following folder: Advanced Options\Delete custom cycles Move the cursor to the cycle you wish to delete. Press Start/Stop key to select/deselect the cycles.
Page 66: Version Handling
Browse to the following folder: Advanced Options\Set external IP address Set the External IP Address as desired. 8.10 Version handling The version handling menu provides tools to import, export, and restore the autoclave software. Browse to the following folder: Main menu\Version Handling You will see the following screen listing the version handling options: Below is the instruction for version handling.
Page 67 Import all settings from USB device In this menu you can import the autoclave’s individual settings from the USB device. The settings include all the changeable parameters of the cycle and the system. Browse to the following folder: Version handling\Import all settings from USB device. The following screen will appear: On this screen, you will see the model name and parameters checksum of the settings saved on the USB device.
Page 68 There is an option to keep the old serial number or calibration data while exporting all the rest from USB. Check/ uncheck respective checkboxes as desired. All the autoclave settings will be imported from the USB device except for the screen above. Import application and setting from USB In this menu you can replace both the application software and the parameters of the autoclave with the software and parameters from the...
Page 69: Cycle Parameters
8.11 Cycle parameters The Cycle parameters menu includes parameters of a specific sterilization program (cycle). Browse to the following folder: Main menu\Cycle parameters You will see the following screen listing the cycle parameters: Note: For all the standard sterilization cycles, and for Bowie and Dick test, the only changeable cycle parameter is dry time (you will not see other parameters on your screen).
Page 70 Pulse B Stay Time Pulse B Low Pressure Pulse B High Pressure Temperature 1 stay Temperature 1 stay time Keep Heat Temperature 2 stay Temperature 2 stay time Sterilization Temperature Heating Sterilization Temperature Sterilization Sterilization Time Cool Mode Cooling (“C” models Cool End Temperature only)
Page 71: Temperature Sensors
8.12 Temperature sensors Temperature sensors \Chamber Temperature In case a machine has a number of temperature sensors, there is an option to assign every chamber temperature sensor to be one of the following: main, reference, not in use. Browse to the following folder: Cycle parameters\Temperature sensors\Chamber Temperature The following screen will appear: Using Up and Down keys, move the cursor around the screen and...
Page 72: Purge (Generator Models Only)
Using the Up and Down keys, choose first, second, or third. The following screen will appear: Using Up and Down keys, move the cursor to the desired radio button and choose it by pressing Start/Stop. 8.14 Purge (generator models only) There is an option to remove the air from the chamber before sterilization.
Page 73: Create Pulse
Change the parameters as desired. 8.15 Create Pulse This menu allows to set parameters for each pulse of the program (see below). Pulse A Count This parameter defines how many times the pulse of each type (A, B) is repeated. For example, if the Pulse count for pulse A (low) is 4, and the Pulse count for pulse B (high) is also 4, the cycle will have the following pulses: low-high-low-high-low-high-low-high.
Page 74: Keep Heat
Pulse A Stay Time This parameter defines the value of delay after the required pressure for the pulse is reached. Browse to the following folder: Cycle parameters\Create Pulse\Pulse A Stay Time Change the parameter as desired. Note: Same parameters are available for other pulses. The following cycles have four pulses pre-vacuum models only): Hollow load, Waste, and Bowie and Dick test.
Page 75 Temperature 1 stay This parameter allows you to set two temperatures at which the process will be paused (Keep Heat). It is possible to set the 2 values (Temp 1 stay and Temp 2 stay). Browse to the following folder: Cycle parameters\Keep Heat\Temperature 1 stay Change the parameter as desired.
Page 76: Heating
Note: same parameters are available for temperature 2. Change the parameter as desired. 8.17 Heating Sterilization Temperature This parameter defines the heating temperature for the cycle. At reaching this temperature, sterilization stage starts. This parameter is equal to the sterilization temperature of the sterilization section (see below).
Page 77 Cool Mode If the setup of your model has the cooling option, and the cycle has the cooling stage, the Cool mode parameter equals 1, otherwise it equals 0. You can set this parameter as 0 or 1 therefore enabling or disabling the cooling option.
Page 78: Exhaust
8.20 Exhaust This menu defines parameters for the exhaust stage. Exhaust Mode The Exhaust mode parameter equals: • 1 for fast exhaust in the end, • 2 for slow exhaust in the end plus opening the fast exhaust when the pressure equals 30 kPa above the ambient pressure, •...
Page 79 Drying stage is divided into two stages. For each stage you can set the total time, on time and off time. So, during the Dry First Stage, the heating elements are on for the time set in Dry Heat On 1, then they go off for the time set in Dry Heat Off 1, and then this sequence is repeated during the entire Dry First Stage Time.
Page 80: Ending
Browse to the following folder: Cycle parameters\Drying\Add Dry Time Change the parameter as desired. 8.22 Ending This menu defines the End temperature parameter for the Ending stage. End Temperature This parameter defines the temperature when the cycle ends. The cycle will not end, and the door will not open unless the autoclave chamber is cooled down to this temperature.
Page 81 Cycle parameters\Global\F0 mode Change the parameter as desired. Check RTC In this menu you can set the time interval for checking the two clocks. The two clocks work during this interval, and the results are displayed. If the results are different for more than 2 seconds, one of the clocks is faulty.
Page 82: Maintenance And Replacement Procedures
9. Maintenance and Replacement Procedures Warning! Do not touch door micro-switches in case of malfunction! Call Tuttnauer service. Preliminary Operations for Each Technician Call To maintain efficient service, the technician must perform the following: Cleaning the following, if requires cleaning: ...
Page 83: Dismantling The Outer Cover Of The Autoclave
Enclosure Leakage Current Test. Every autoclave should pass this test as follows: Connect the electrical cord to the autoclave. Turn on the main switch on the right side of the autoclave. Short-circuit the L and N pins on the cord's plug. Connect the Short-circuit pins to the L pole on the electrical tester.
Page 84: Replacing The Chamber Heater
Replacing the chamber heater 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. Allow the autoclave to cool before removing outer cover. Take off the autoclave covers. Remove the insulation blanket.
Page 85: Checking The Safety Valve Type 1
9.5 Checking the Safety Valve Type 1 Note: To prevent the safety valve from becoming blocked, it is necessary to allow the steam pressure to escape through it (every month). To avoid injuries, begin this check while the autoclave is cold . Operate the sterilization cycle according to the manual .
Page 86: Replacing The Safety Valve Type 1
Rear wall Rear wall ASME ASME Rear wall Replacing the Safety Valve Type 1 Caution! Before starting, be sure that the electric cord is disconnected and that there is no pressure in the autoclave. Note: this instruction refers to both, PED and ASME approved safety valves Remove the outer cover of the autoclave.
Page 87: Checking The Safety Valve Type 2 ("Apollo")
Test autoclave cycles. Description Cat. No. No. Description Cat. No. PED 2.8 Safety valve SVL029-0028 6 CMV100-0004 Chamber base safety ASME valve SVL029-0090 7 Screw BOL190-0150 40 psi 10.6 Checking the Safety Valve type 2 (“Apollo”) Operate the sterilization cycle according to the manual. Allow a pressure of approximately 200 kPa (29-psi) to build up in the chamber.
Page 88: Replacing The Safety Valve Type 2 ("Apollo")
Wait until the pressure decreases to zero, only then can the door be opened. valve’s handle 10.7 Replacing the Safety Valve type 2 (“Apollo”) Disconnect the pipe connection. Unscrew the safety valve (including the base) and remove from the autoclave. Replace it with a new safety valve (use an original only).
Page 89: Replacing The Door Cover (Automatic Door)
Replacing the Door Cover (Automatic Door) Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the chamber or the generator. Allow the autoclave to cool before opening the service doors. To avoid injuries, replace the gasket while the autoclave and the autoclave door are cold.
Page 90 Assembling the door cover Take the door bolt covers and insert the 3 moulded pins into the three corresponding holes, then pull them from inside until they lock into place (see the figure below). Place the cable (2) in its place behind the bridge as shown on the figure below.
Page 91: Replacing The Door Cover (Md -- Mechanic Door)
Use 10 screws (1) to assemble the new door cover to the bridge. Do not tighten the screws to allow the door cover final alignment. Close the door and align the cover so it is parallel to the autoclave body in all planes. Note: Open and close the door slowly so as not to disturb the alignment achieved in step 6.
Page 92 Insert a screwdriver in the holes on the sides of the door cover (7) and unscrew the 4 screws (14) assembling the door cover to the door. Remove the door cover. Be careful not to lose the second sliding spacer (placed between the closing arm and the door cover). Page 91...
Page 93 9.9.2 Assembling the door cover Assemble the following items to the door cover: • The inner closing arm support (8). • The connector of the door cover to the door hinges (9). • The connector of the door cover to the door (10). Open the autoclave's door.
Page 94 Insert 4 screws (15) to assemble the door cover to the door (part 9 to part 12 and part 10 to part 13) Insert a screwdriver (17) in the holed (7) on the sides of the door cover and tighten the 4 screws (15). Keep a gap of approx. 4 mm between the door cover and the top of the autoclave.
Page 95: Replacing The Door Gasket - Md Models (Mechanical Door)
Tighten the screw (3) attaching top part of the inner closing-arm guide (5) to the door cover. Do this with a screwdriver inserted through the hole (2) in the side of the door cover. Close the door. Tighten screw 6 (on bottom of closing-arm guide). Do this with a screwdriver inserted through the hole (1) in the rear of the door cover.
Page 96: Replacing The Door Gasket - D Models (Automatic Door)
Tighten all the screws (2, 6) of the segments. Description Cat. No. Fastener, Door Gasket, Segment, 50XX LOK507-0042 Screw M5 x 16 BOL191-0162 Gasket, Door, Silicon, Va. Res., 50xx GAS080-0043 Screw M5 x 25 BOL191-0240 Spring lock washer M5 NUT193-0325 Nut M5 NUT192-0192 9.11...
Page 97 Note: It is necessary to use a silicone-based lubricant such as Würth Silicone Lubricant or Dow Corning 111, when installing the door gasket. If you had purchased a replacement door gasket, from Tuttnauer, it will have come with a small packet of Würth Silicone lubricant.
Page 98: Replacing The Door Micro-Switch 1 (Automatic Door Only)
Replacing the Door Micro-Switch 1 (Automatic Door only) Warning! Do not touch door micro-switches in case of malfunction! Call Tuttnauer service. Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the autoclave.
Page 99: Replacing The Door Micro-Switch 2 (Automatic Door Only)
Replacing the Door Micro-Switch 2 (Automatic Door only) Warning! Do not touch door micro-switches in case of malfunction! Call Tuttnauer service. 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.
Page 100: Replacing The Panel And Its Components
Caution: Make sure that the door switch is installed correctly! Check that you see the operational message “Door is Open” on the display when you open the door and that the message disappears when you close it. 9.14 Replacing the Panel and its Components Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the autoclave.
Page 101 Unscrew the five side fastening screws (1). Pull the panel out for approx. 30 centimeters. Remove the protective cover (2) Remove the digital I/O card (4) and the main card (5). Page 100...
Page 102: Replacing The Printer Door
Disconnect the PCB connectors (3) Remove the display (4) and the keypad (5). To do so, unscrew and disconnect the display, then pull the keypad inwards. Remove the printer (3) (see sec. 9.16 "Replacing the Printer"). Assemble the above parts (see steps 7-10) on the new panel. Assemble the panel and fasten it to the autoclave with the 4 fastening screws (see step 1).
Page 103: Replacing The Printer
9.16 Replacing the Printer Caution Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the autoclave. Allow the autoclave to cool before opening the service door. Remove the panel (see sec. 9.14 Replacing the Panel) to reveal the internal part and the electrical connectors.
Page 104 The printer (6) is fastened to its seat with two fasteners (5). To release the fasteners, using a flat screwdriver, press slightly on the part marked (4) and pull the fastener upward. Repeat this with the second fastener. Pull the printer out of its seat (the hole in the panel). Replace the printer with a new printer.
Page 105: Replacing The Main Switch
9.17 Replacing the main switch Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the chamber. Allow the autoclave to cool before dismantling the outer covers. Remove the control electronic boards. Disconnect all the four wires.
Page 106: Replacing The Fuse Of The Transformer
9.18 Replacing the fuse of the transformer Caution! Before starting, disconnect the instrument from the power source. Allow the autoclave to cool before dismantling the outer covers. Remove the autoclave covers (see para. 9.3 “Dismantling the Outer Covers of the Autoclave”). If necessary, cut one plastic cable holder to release the fuse capsule (1).
Page 107: Replacing The Plunger Or Coil Of The 1/4" Solenoid Valve
9.19 Replacing the Plunger or Coil of the 1/4" Solenoid Valve The solenoid valves may be out of order due to faulty plunger or coil. To repair the solenoid valve – replace the faulty plunger or solenoid. Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the chamber.
Page 108: Replacing The Plunger Or Coil Of The Baccara Solenoid Valve
9.20 Replacing the Plunger or Coil of the BACCARA Solenoid Valve The solenoid valves may be out of order due to faulty plunger or coil. To repair the solenoid valve – replace the faulty plunger or solenoid. Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the chamber.
Page 109: Replacing The Air Filter
Unscrew the plunger + spring (4) with the plunger housing (3) and replace it with a new one. The plunger the spring and the housing are replaced as a kit. Reassemble the coil (2) and the nut (1). Re-install the autoclave cover. 9.21 Replacing the Air Filter Caution!
Page 110: Replacing The Pressure Transducer
Note: It is recommended to replace the air filter once a year. 9.22 Replacing the Pressure Transducer Caution! Before proceeding, make sure that the electric cord is disconnected and there is no pressure in the autoclave. Remove the autoclave outer covers. Unscrew the screw (1).
Page 111: Replacing The Circuit Breaker
Unscrew the 6 screws (3). Remove the old circuit breaker and replace it with a new one. Use only an original circuit breaker supplied by Tuttnauer. Assemble the new circuit breaker with the 6 screws (3). Connect the electrical connections (3).
Page 112: Replacing The Power Supplies, Water Level Board And Relays
9.24 Replacing the power supplies, water level board and relays Caution! Before starting, be sure that the electric cord is disconnected from the power source and that there is no pressure in the autoclave generator. Allow the autoclave to cool for about an hour before removing outer covers.
Page 113 The autoclave electric box Description of Items Photo Cat. No. Description ELE035-0144 Power Supply 24VDC (1A) Page 112...
Page 114: Replacing The Safety Pressure Switch
Unscrew and remove the pressure switch (2) from its seat (3). Replace the pressure switch with a new one, use only an original pressure switch supplied by Tuttnauer. Assemble the pressure switch (2) to its seat (3). Connect the electrical connections (1).
Page 115: Replacing The Fan Of The Electronic Unit
9.26 Replacing the Fan of the Electronic Unit Caution! Before starting, disconnect the autoclave from the power source. Allow the autoclave to cool before dismantling the outer covers. Remove the autoclave covers (see para. 9.3 “Dismantling the Outer Covers of the Autoclave”). Unplug the fan plug (1).
Page 116: Replacing The Water Reservoir Electrode /Float
9.27 Replacing the Water Reservoir Electrode /Float Open the cover. Disconnect the wires of the float (1) Unscrew the white plastic nut (2) Pull out the old float (3); insert the new float in the correct direction. Apply some leakage prevention glue inside the nut and tighten it. Reconnect the wires and close the cover.
Page 117: Replacing The Door Switch
9.28 Replacing the Door Switch Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the chamber. Allow the autoclave to cool before removing outer covers. Remove the autoclave covers (see para. 9.3 “Dismantling the Outer Covers of the Autoclave”).
Page 118 Page 117...
Page 119: Troubleshooting
10. Troubleshooting Warning! Do not touch door micro-switches in case of malfunction! Call Tuttnauer service. Only technical personnel having proper qualifications and holding technical documentation (including a technician manual) and adequate information are authorized to service the apparatus. Possible causes Check-...
Page 120 Possible causes Check- Symptoms Corrective Action ups and tests Check 24V input to the printer. If none: ⎯ Discontinuity between power supply and printer. ⎯ Faulty power supply. The door gasket is Clean the door gasket. dirty. (See Daily Maintenance in leaking at the (See Daily Maintenance in Operator's manual).
Page 121 Possible causes Check- Symptoms Corrective Action ups and tests If the problem persists, perform the following with SSR, Analog During the 'Ending' stage board, and temp/pressure the chamber temperature sensors: does not go below the temperature defined in Test parameter 'End If this doesn’t help, Temperature' for X minutes recalibrate.
Page 122 Possible causes Check- Symptoms Corrective Action ups and tests During 'Sterilization' stage, If the problem persists, perform the chamber temperature the following with SSR, Analog goes above the value board, and temp/pressure defined in parameter sensors: 'Sterilization Temperature' + value of parameter Test If this doesn’t help, 'Sterilization temperature...
Page 123 Possible causes Check- Symptoms Corrective Action ups and tests Temperature' using a predefined lookup table. Possible causes: Heating elements go on working beyond the required time. Faulty SSR or Analog board. Faulty calibration of temperature or pressure sensors. Faulty temperature or pressure sensors.
Page 124 Possible causes Check- Symptoms Corrective Action ups and tests Door gasket is leaking. Heating elements (even one of them) do not work. Faulty SSR or Analog board. Faulty calibration of temperature and pressure sensors. Faulty temperature or pressure sensors. Chamber pressure has not If the problem persists, replace reached the requested high the door gasket.
Page 125 Possible causes Check- Symptoms Corrective Action ups and tests clogged. electrode. Replace the water pump Water level electrode fuse. is dirty. The wire of the water level electrode is disconnected. Faulty water pump. One of the heating elements does not work Faulty thermostat Faulty cut-off If it happened before or during the...
Page 126 Possible causes Check- Symptoms Corrective Action ups and tests Water I/O Transformer Fuses Vacuum Time Error Perform a new cycle. message on the yellow If the problem persists, perform screens after a failed cycle vacuum test to find leakage the means that, during a time autoclave door or pipes.
Page 127: List Of Spare Parts
Hex Socket Cap Screw, 1/4UNCx1, St. St. A2 BOL191-0091 Pan Head Machine Screw, Phillips, M4X20, St. St. A2, DIN7985 CMT507-0052 Bracket, safety valve support for 5050/75 LOK507-0020 Solenoid Housing for 60x60-A, 60x90-A-ALFA LOK507-0031 Guide, door locking arm, short, assembly, 50XX...
Page 128 Part Number Description LOK240-0026 Tightening Bolt, Door Locking Bellows HEA012-0010 Heating Element, Band, 230V, 19-3/4"x3-1/2",1100W, Copper,50XX ML/EL BOL194-0330 Blind Rivets 4x10, Head 7.5 mm, Aluminium, DIN7337 A ARM100-0139 Steam trap, 1/4" BSP, St. St. CMT067-0014 Strainer 1/4BSP, Complete FIL175-0046 Screen, 400 Micron, For Strainer 1/4" GAS082-0008 Gasket, Silicon, 4mm, OD=28mm, ID=20mm for 1/4"...
Page 129 Part Number Description SOL026-0018 Coil, Solenoid, 24VAC, 8W, 50Hz, Bac. SOL026-0032 Valve, Solenoid,Brass, 2/2 way,1/4"BSPx4.0, NC,GEM-A- 22017,Baccara ELC258-0015 Sensor, Temperature, 5x100, 54400, Sontec, Assy. (For D line) GAS080-0022 O-Ring, ID 2.84, W=2.62, 2-104 EPDM THE003-0002 Sensor, Temperature, PT100, 5x100, Sontec FIL175-0087 Filter, Water, PVC Assy.
Page 130 Part Number Description GAU029-0059 Pressure Regulator, Water, In-Line with Strainer, 1/4"BSP, 1.5 Bar GAU029-0062 Pressure Regulator, Water, In Line with Strainer, 1/4"BSP, 0.5 Bar SOL026-0018 Coil, Solenoid, 24VAC, 8W, 50Hz, Bac. SOL026-0032 Valve, Solenoid,Brass, 2/2 way,1/4"BSPx4.0, NC,GEM-A- 22017,Baccara ARM172-0007 Check Valve, Spring Disk, 1/4"NPT, St.St. GAS086-0017 Tube, Teflon, 6x8mm PUM057-0008...
Page 131 Part Number Description DIN7985 CTP201-0065 Relay, SSR,24-280VAC,25A,Contr. 3-32VDC, SPST- NO,Screw terminals CTP201-0271 Relay Socket CTP201-0272 Miniature PCB relay, coil 24VDC, contact 250VAC, 8A, 2 pole CTP201-0318 Fan, 24VDC, Dia. 80mmx20mm, 34.6CFM ELE034-0026 Contactor, DILM12-230V, 20A ELE035-0011 Fuse, 5x20mm, Glass tube, 250V, 6.3A, SB ELE035-0011 Fuse, 5x20mm, Glass tube, 250V, 6.3A, SB ELE035-0090...
Page 132 Part Number Description BOL191-0070 Flat Head Machine Screw, Phillips, M4x10, St. St. A2, DIN965 ELE035-0052 Circuit Breaker, 3-pole, 277VAC/80VDC,15A NUT192-0230 Nut,Clip-On,U-Style,4.8x20x13,0.7 thick.,Spring steel,Cadmium plated THE005-0009 Thermostat, CUT-OFF, TY95-H, 255C, Campini THE005-0010 Thermostat, Safety, TY95-H, 230C, Campini WIR040-0179 Modular coupler, MH3101S-8821 Shielded Cat 5e, MH connectors ELE039-0049 Connector, Ceramic, No.1, single...
Page 133: Water Outlet Strainer
Part Number Description TRY505-0001 Shelf for ML, EL 5050 CMT196-0001 Bushing, water level electrode GAS086-0001 Tube, Teflon, Water Level Electrode ELE039-0048 Terminal, male, brass, w/o isolation, PC1L18704LR, K.S. Terminals FIT100-0226 Nut for Sleeve, Tube 1/4, Thread 7/16-24, Brass NUT192-0191 Hex Nut, M4X3.2, Stainless Steel A2, DIN934...
Page 134: Pressure Vs Temperature For Saturated Steam
12. Pressure vs Temperature for Saturated Steam psia InHg °F °C psia psig °F °C 2.95 114.5 0.10 45.8 17.1 219.7 1.18 117.9 104.3 4.44 129.3 0.15 54.1 17.2 219.9 1.18 118.6 104.4 5.90 140.2 0.20 60.1 17.2 220.1 1.19 118.6 104.5 7.39...
Page 135 psia InHg °F °C psia psig °F °C 15.4 214.3 1.06 106.2 101.3 18.6 224.1 1.28 128.1 106.7 15.5 214.5 1.07 106.6 101.4 18.6 224.2 1.29 128.5 106.8 15.5 214.7 1.07 106.9 101.5 18.7 224.4 1.29 129.0 106.9 15.6 214.9 1.07 107.3 101.6...
Page 136 psia InHg °F °C psia psig °F °C 17.1 219.6 1.18 117.5 104.2 20.4 229.1 1.41 140.9 109.5 20.5 229.3 1.41 141.4 109.6 24.6 239.2 1.70 169.7 115.1 20.6 229.5 1.42 142.0 109.7 24.7 10.0 239.4 1.70 170.2 115.2 20.6 229.6 1.42 142.4...
Page 137 psia InHg °F °C psia psig °F °C 22.1 233.2 1.52 152.2 111.8 26.4 11.7 243.1 1.82 182.2 117.3 22.1 233.4 1.53 152.7 111.9 26.5 11.8 243.3 1.83 182.8 117.4 22.2 233.6 1.53 153.2 112.0 26.6 11.9 243.5 1.83 183.4 117.5 22.3 233.8...
Page 138 psia InHg °F °C psia psig °F °C 23.8 237.4 1.64 164.2 114.1 28.5 13.8 247.3 1.96 196.1 119.6 23.9 237.6 1.65 164.8 114.2 28.6 13.9 247.5 1.97 196.7 119.7 24.0 237.7 1.65 165.3 114.3 28.6 13.9 247.6 1.97 197.3 119.8 24.1 237.9...
Page 139 psia InHg °F °C psia psig °F °C 30.7 16.0 251.4 2.11 210.8 121.9 36.0 21.3 261.0 2.48 248.3 127.2 30.8 16.1 251.6 2.11 211.5 122.0 36.1 21.4 261.1 2.49 249.1 127.3 31.0 16.3 251.8 2.12 212.1 122.1 36.2 21.5 261.3 2.50 249.9...
Page 140 psia InHg °F °C psia psig °F °C 32.8 18.1 255.6 2.26 226.5 124.2 38.6 23.9 265.1 2.66 266.2 129.5 32.9 18.2 255.7 2.27 227.2 124.3 38.7 24.0 265.3 2.67 267.0 129.6 33.0 18.3 255.9 2.28 227.9 124.4 38.8 24.1 265.5 2.68 267.8...
Page 141 °C °F psig psia °C °F psig psia 135.6 318.6 3.19 276.1 31.7 46.2 131.6 283.4 2.83 268.9 26.4 41.1 135.7 319.5 3.20 276.2 31.9 46.3 131.7 284.3 2.84 269.1 26.5 41.2 135.8 320.5 3.20 276.4 32.0 46.5 131.8 285.1 2.85 269.2 26.7 41.4 135.9 321.4 3.21 276.6 32.1 46.6 131.9 286.0 2.86 269.4 26.8 41.5 136.0 322.4 3.22 276.8 32.3 46.8 132.0 286.8 2.87 269.6 26.9 41.6 136.1 323.3 3.23 277.0 32.4 46.9 132.1 287.7 2.88 269.8 27.0 41.7...
Page 142 °C °F psig psia °C °F psig psia 137.9 340.4 3.40 280.2 34.7 49.4 133.9 303.3 3.03 273.0 29.3 44.0 138.0 341.4 3.41 280.4 34.8 49.5 134.0 304.2 3.04 273.2 29.4 44.1 138.1 342.4 3.42 280.6 35.0 49.7 134.1 305.1 3.05 273.4 29.5 44.2 138.2 343.4 3.43 280.8 35.1 49.8 134.2 306.0 3.06 273.6 29.7 44.4 138.3 344.4 3.44 280.9 35.2 49.9 134.3 306.9 3.07 273.7 29.8 44.5 138.4 345.4 3.45 281.1 35.4 50.1 134.4 307.8 3.08 273.9 29.9 44.6...
Page 143: Valves Numbering
13. 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)
Page 144 Filtered air - inlet Air Inlet Aeration Vacuum - break Vacuum - to pump VACUUM 53.1 Vacuum - from door 1 seal 53-2. Vacuum - from door 2 seal Drain – from reservoir Drain – from jacket overflow Drain – from vacuum pump / ejector Drain –...
Page 145 Steam – from building source Steam – to jacket (From outer source) Steam – inlet Steam – to chamber 94 – 1. Steam – to door 1 seal STEAM 94 – 2. Steam – to door 2 seal Steam – to heat exchanger Steam –...
Page 146: Drawings
14. Drawings 14.1 PIPING DRAWING – MODEL 5050, 5075 EL/ ELPRC-MD Page 145...
Page 147 14.2 PIPING DRAWING – MODEL 5050, 5075 ELPV-MD Page 146...
Page 148: Piping Drawing - Model 5050, 5075 Elc-Md (380/400V)
14.3 PIPING DRAWING – MODEL 5050, 5075 ELC-MD (380/400V) Page 147...
Page 149: Piping Drawing - Model 5050, 5075 Elcpv(F)-Md (380/400V)
14.4 PIPING DRAWING – MODEL 5050, 5075 ELCPV(F)-MD (380/400V) Page 148...
Page 150: Piping Drawing - Model 5050-5075 Elcbh D
PIPING DRAWING – MODEL 5050-5075 ELCBH D 14.5 Page 149...
Page 151: Piping Drawing - Model 5050- 5075 El-Bh (F) D
PIPING DRAWING – MODEL 5050- 5075 EL-BH (F) D 14.6 Page 150...
Page 152: Electrical Wiring Diagram - Model 5050/5075 El(C)(Pv)(Bh)(F) (230V)
14.7 ELECTRICAL WIRING DIAGRAM – MODEL 5050/5075 EL(C)(PV)(BH)(F) (230V) Page 151...
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Page 158 Page 157...
Page 159 Page 158...
Page 160: Electrical Wiring Diagram - Model 5050/5075 El(C)(Pv)(Bh)(F) (380/400V)
14.8 ELECTRICAL WIRING DIAGRAM – MODEL 5050/5075 EL(C)(PV)(BH)(F) (380/400V) Page 159...
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Page 162 Page 161...
Page 163 Page 162...
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Page 167 Page 166...
Page 168: Switch Box Wiring Diagram
14.9 Switch Box Wiring Diagram To enable the connection of the autoclave to the 1 phase electrical net, a special switch box is supplied with the autoclave. This switch box shall be placed on the wall and the wiring connection shall be as described below.
Page 169: Open Switch Box
14.10 Open Switch Box FROM FROM AUTOCLAVE NETWORK Page 168...
Page 170: Closed Switch Box
14.11 Closed Switch Box Page 169...

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