Tuttnauer 3840 ELVG-D Technician Manual
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Tuttnauer 3840 ELVG-D Technician Manual

Electronic laboratory autoclaves
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Technician Manual
Electronic Laboratory Autoclaves
Models 3840, 3850, 3870 ELVG-D
ELVG-D: standard autoclave
C: optional system for fast cooling
PV: optional vacuum pump
BH: optional bio hazard filtration
F: optional fan for super-fast cooling
Cat. No. MAN205-0491000EN Rev. F
Tuttnauer Europe B.V.,
Hoeksteen 11 4815 PR P.O. Box 7191 4800 GD Breda,
The Netherlands  Tel: 31 (0) 765423510,  Fax: 31 (0) 765423540
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  • Page 1 BH: optional bio hazard filtration F: optional fan for super-fast cooling Cat. No. MAN205-0491000EN Rev. F Tuttnauer Europe B.V., Hoeksteen 11 4815 PR P.O. Box 7191 4800 GD Breda, The Netherlands  Tel: 31 (0) 765423510,  Fax: 31 (0) 765423540...
  • Page 2 http://www.tuttnauerusa.com/...

  • Page 3: Table Of Contents

    Table of Contents Paragraph , page no. Introduction Installation Instructions Installation Site Connection of the pressure regulator Front View Front View for the Fan Configuration Rear View Tests Installation Tests Periodical Tests Technical Data Directives and Standards Water Quality Reverse Osmosis Electrical data Specifications Overall Dimensions...

  • Page 4: Replacing The Door Micro-Switch

    6.11 Cycle parameters 6.12 Temperature sensors 6.13 Displayed inputs 6.14 Purge (generator models only) 6.15 Create Pulse 6.16 Keep Heat 6.17 Heating 6.18 Sterilization 6.19 Cooling (“C” models only) 6.20 Exhaust 6.21 Drying 6.22 Ending 6.23 Global (for some models only) Generator description Generator Electrical Safety System The Water Pump for the Steam Generator...
  • Page 5 Replacing the Generator Side Gauge Glass Indicator Tube Replacing the Generator Thermostat The Water Pump Replacement Releasing the Vacuum Pump Rotor 10. Troubleshooting 10.1 Autoclave Troubleshooting 10.2 Steam Generator Troubleshooting 11. List of Spare Parts 11.1 Water Outlet Strainer 12. Pressure vs Temperature for Saturated Steam 129 13.

  • Page 6: 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 7 A special feature of the autoclave is the fast cooling stage for liquids. In this stage pressure in the chamber is increased by means of compressed air to compensate the fast decreasing of pressure due to the fast cooling. The fast cooling shortens the time required for safe handling of bottles There is a configuration equipped with fan that allows to shorten the cooling operation.

  • Page 8: Installation Instructions

    2. Installation Instructions The following utilities have to be connected (Refer to the drawing below ‘Rear View’ of the autoclave).  Power outlet, as detailed in the table below: Power 3 Ph, 400V/50/60Hz Recommended Circuit Breaker  If the 3 phase autoclave has to 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 9: Installation Site

    2.1 Installation Site Install the autoclave according to the following guidelines: Place the autoclave on the floor. Verify that the surface is leveled. All utility supplies must be prepared in accordance with requirements, before autoclave installation e.g. mineral-free and tap water, compressed air, one or three-phase power network, connection to the drain of the building.
  • Page 10 FLOW DIRECTION Page 8...

  • Page 11: Front View

    2.3 Front View No. Description Description Front leg Display Rear leg Keyboard Left service door Printer cover Left service door grip Paper slot and paper cutter Left service door lock USB socket Door cover Main switch Pressure gauge Printer Page 9...

  • Page 12: Front View For The Fan Configuration

    2.4 Front View for the Fan Configuration There is a configuration equipped with a fan that allows shortening the cooling operation. The fan is located on the door of the autoclave. Page 10...

  • Page 13: Rear View

    2.5 Rear View Description Description air pressure regulator fan grill generator drain outlet RJ45 connector tap water inlet circuit breaker mineral free water inlet electrical socket generator pressure gauge gravitation valve for vacuum pump side gage glass indicator tube compressed air inlet generator safety relief valve autoclave air pressure gauge chamber safety relief valve...

  • Page 14: Tests

    3. Tests 3.1 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 15 Perform validation of the autoclave. Check the precise operation of the earth leakage relay. Check that the autoclave is leveled. Check the safety elements; safety valve, safety and cut-off thermostats door locking mechanisms. Run basic programs of the autoclave and check the operation sequences, the sterilization parameters etc.

  • Page 16: Technical Data

    4.1 Directives and Standards Tuttnauer. Ltd. company meets the provisions of the following standards: 9001:2008 (Quality Systems) Tuttnauer. Ltd. company also works in conjunction with and refers to: ANSI/AAMI ST55 American Society of Mechanical Engineers Section VIII, Division 1, for unfired pressure vessels.

  • Page 17: Reverse Osmosis

    Phosphate (P ≤ 0.5 mg/l ≤ 0.1 mg/l Conductivity (at ≤5 µs/cm ≤ 3 µs/cm 25°C) pH value (degree of 5 to 7.5 5 to 7 acidity) Hardness (Σ ions of ≤ 0.02 mmol/l ≤ 0.02 mmol/l alkaline earth) Appearance Colorless, clean, without sediments [Minimum specific resistivity of 1 megohm per cm (1 MΩ/cm)] Compliance with the above data should be tested in accordance with...

  • Page 18: Electrical Data

    4.4 Electrical data 230V configuration Value: Value: Value: Property 3840 3850 3870 Total Power 9000 9000 9000 1Ph, 1Ph, 1Ph, Voltage 230VAC 230VAC 230VAC 22A w/o 22A w/o 22A w/o Amperage PV, 25A PV, 25A PV, 25A with PV with PV with PV Protection against electrical Class I (IEC 60601-1)

  • Page 19: Specifications

    4.5 Specifications Model Properties 3840 3850 3870 Chamber diameter Chamber depth Chamber volume 52 liters. 65 liters. 85 liters. Height 1000 1000 1000 Overall dimensions Width Length Maximum Width dimensions Length 1500 1500 1500 (door open) Net weight (kg) 105kg 108kg 113kg Shipping volume...

  • Page 20: Overall Dimensions

    4.6 Overall Dimensions 4.7 Construction Chamber and door Stainless steel material Outer Cabinet Stainless Steel Fiberglass with reinforced Chamber insulation material Page 18...

  • Page 21: Utilities

    4.8 Utilities 4.8.1 Electrical utility Recommended Switch Power Circuit Breaker 208-220V (3 Ph + Earthing) 380-400V(3 Ph + Neutral + Earthing) 230V 1ph Frequency 50/60Hz 4.8.2 Other Utilities Compressed Air 1/2" 3-4 Bar (44-58 psi) (ELVCPVG-D only) Tap water 1/2", 2-3 Bar (29-44 psi) Mineral free water 1/2", 2-3 Bar (29-44 psi) 2"...

  • Page 22: Symbol Description

    4.9 Symbol Description Caution! Consult accompanying documents Caution! Hot surface. Caution! Hot steam. Protective earth (Ground) On-Off Page 20...

  • Page 23: Description Of The Control System

    5. Description of the Control System. 5.1 Hardware Control System Components: Block Diagram Main board CPU +memory- Backup 24/12 I/O Board 24/12 power input CPU- STM32F103R6T6 Input MCIMX27LVOP4A+MC13783VK5 Input -24 Digital Outputs R.T.C (including Battery) -2 Analog outputs COM1 M41T81SM6E (RS232) -9 Digital inputs MAX323...

  • Page 24: Interfaces To Users

    Mapping of the software to the hardware – see Software Development Plan. The Hardware architecture is based on Freescale i.MX27 PDK Evaluation Board. 5.3 Interfaces to Users Keypad: The keypad has three push buttons: Down key Up key Start/stop key Display: The control system has a graphical display USB socket:...
  • Page 25 Digital inputs Digital Inputs Door closed J12/1 Door unlocked J12/6 Door locked J12/8 Digital outputs Digital Outputs Steam to jacket J13/8 Vacuum pump J13/12 Exhaust to bio J13/14 Main exhaust J13/16 Atmospheric air valve J14/2 Compressed air to chamber J14/4 Slow exhaust J14/6 Fast exhaust...

  • Page 26: Hardware Control System Components

    5.5 Hardware Control System components The hardware is consisted of cards: MAIN and IO Main card Ethernet Connector Connector Power Supply Lithium coin Connector Connector Not in use to Keypad to IO Board battery T.H orizontal 3V 4V DC) 48mAh Connector to Connector to Connector...
  • Page 27 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 IO Card...
  • Page 28 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. At the end of the check process of the digital and analog ports, the communication channel is checked, in case of receiving a request, the request is checked and if the request is legitimate it will be taken care...
  • Page 29 Communication protocol between IO to Main boards is described below. The communication manged by the Main board (master), the IO functions as slave. There are six communication functions. The communication functions (to read or write) identified by number. The communication functions listed below: Read –...

  • Page 30: Checking And Changing Parameters And Other Data

    6. 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), with the exception of the Temperature sensors, Displayed inputs, and Dry Time.

  • Page 31: 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 32 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 30...

  • Page 33: 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 6.3 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 34 Below you can find instructions how to login and enter the Main menu. Section 7.1 above explains how to browse through the menus; section 7.2 explains how to change a parameter. Below is the explanation of the Quick Options. 6.3.1 Export to USB his subdirectory allows you to export settings and cycles history to the USB device.
  • Page 35 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. 6.3.2 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 36 Choose Print last cycle, Print last 5 cycles, or Print last 10 cycles. Press the Start/Stop key. The cycle reports will be printed. 6.3.3 Version Information This directory allows viewing information of the current, factory default, and previous software versions. Enter the Version information screen.
  • Page 37 On the Start cycle by clock screen, the time is displayed in the form “HH:MM”. The hour range is 24 hours (i.e. from "0" to "24"). Setting the time to start the cycle Move the cursor to the Time field. Set the required time.
  • Page 38 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. 6.3.5 Set date and time This subdirectory enables the operator to set date and time.

  • Page 39: Logging In And Entering The Main Menu

    Caution! After setting time and date, turn the autoclave off and then on again. 6.4 Logging in and entering the Main menu Below you can find instructions how to login and enter the Main menu. Section 7.1 above explains how to browse through the menus, section 7.2 explains how to change a parameter.

  • Page 40: Directories And Subdirectories

    Choose Technician, then press the Start/Stop key to enter. The following screen will appear: 0000 is displayed on the screen with the cursor flashing on the right digit.  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.
  • Page 41 To learn how to scroll through the menus, change the parameters, and perform some other functions using our three-button keypad, see 6.1 and6.2. The following table lists the options that the technician may perform. Directory Subdirectory Temperature sensors Displayed inputs Purge (generator models only) Drying Create Pulse...
  • Page 42 Directory Subdirectory View analog inputs state Analog inputs calibration Export gain offset to USB Import gain and offset from USB Reset atmospheric pressure Maintenance Test RTC Printer test Print all gain and offset Enable cycles Set Language Set temperature units Advanced Options Set pressure units Duplicate cycles...

  • Page 43: System Parameters

    6.6 System Parameters This menu is listing the system parameters that are the same for all cycles. Browse to the following folder: Main menu\System parameters You will see the following screen: Below is the instruction for changing the system parameters. 6.6.1 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.
  • Page 44 Browse to the following folder: System parameters\Print Rate All Change the parameter as desired 6.6.2 Print Rate Sterilization In this menu you can define the time interval for printing out the cycle status during the sterilization stage: The default is 1 minutes. Browse to the following folder: System parameters\Print Rate Sterilization Change the parameter as desired...

  • Page 45: Inputs/Outputs

    6.6.7 Temperature calibration low In this menu you can define the low calibration point for temperature.. Browse to the following folder: System parameters\Temperature calibration low Change the parameter as desired 6.6.8 Cycle Print Gap This parameter defines the time interval between printing the current values of the cycle (See the printer output section).
  • Page 46 Browse to the following folder: Inputs/Outputs\View digital inputs state 6.7.2 View digital outputs state In this menu you can view, at any stage, which digital outputs are being controlled at the moment. Browse) to the following folder: Inputs/Outputs\View digital outputs state 6.7.3 Test digital outputs In this menu you can view the normal function of all the autoclave elements: valves, heating elements, pumps, etc.
  • Page 47 Press Up or down key to choose the input to calibrate and press Start/Stop. The following screen will appear: See below description of each option. 6.7.6 Auto calibrate Bacsoft software has an option for automatic calibration using the PT100 simulator. On the calibration options screen, choose Auto calibrate.
  • Page 48 6.7.7 Calibrate analog input This menu allows calibrating analog inputs manually. On the calibration options screen, choose Calibrate analog input. The following screen will appear: In the Actual field, change the high and low values of the input as desired. 6.7.8 Set gain and offset On the calibration options screen, choose Set gain and offset.
  • Page 49 Change gain and offset as desired. 6.7.9 Restore last calibration There is an option to restore the gain and offset values set at previous calibration. On the calibration options screen, choose Restore last calibration. The following screen will appear: Using the up and down keys, move your cursor to confirm and press Start/Stop.
  • Page 50 6.7.10 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. The following screen will appear: Using the up and down keys, move your cursor to confirm and press Start/Stop.

  • Page 51: Maintenance

    6.8 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: Below is the instruction for autoclave’s maintenance menu. 6.8.1 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.
  • Page 52 6.8.2 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. Browse to the following folder: Maintenance\Import gain and offset from USB Press Start/Stop.
  • Page 53 Leave the door open for 2 minutes at least. Ambient temperature should be less than 45°C. Note: Please reset the atmospheric pressure when you install the autoclave for the first time, and each time you relocate or calibrate the autoclave. 6.8.4 Test RTC In this menu you can check the two clocks.
  • Page 54 Using the Up and Down keys, move the cursor to Exit. 6.8.5 Printer test In this menu you can check the normal function of the printer. The printer will print the list of errors. Browse to the following folder: Maintenance\Printer test The following screen will appear to confirm that the test has been done.

  • Page 55: Advanced Options

    Browse to the following folder: Maintenance\Print all gain and offset See below the example of a printout: Chamber Temperature G:000.0385;O:-008.0976 Chamber Pressure G:000.1238;O:-098.5985 Chamber Water Level G:001.0000;O:000.0000 Mineral Free Water Level G:001.0000;O:000.0000 6.9 Advanced Options Advanced options menu gives you even more possibilities, including interface customization, changing the settings, enabling, adding and deleting cycles, etc.
  • Page 56 Below is the instruction for the Advanced options menu. 6.9.1 Enable cycles In this menu you can enable only the cycles you want to use. The cycles you do not want to use will not appear on the screen. Browse to the following folder: Advanced Options\Enable cycles Move cursor to the cycles you want to enable/disable and check/unchek them as desired.
  • Page 57 Note: There are more languages than you see on the screen above. Just scroll down to see more. Move the cursor to the desired language and check it. The following screen will appear: The machine will be restarted and the main screen (current cycle) will appear in the chosen language.
  • Page 58 6.9.4 Set pressure units In this menu you can 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 6.9.5 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 59 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 6.4). In the main menu, select Cycle parameters and enter the Cycle Parameters screen.
  • Page 60 Now you can alter the cycle parameters as desired. 6.9.6 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 61: Version Handling

    6.9.7 Set external IP address This option allows to set specific external IP address to be used for remote RCPR connection. Browse to the following folder: Advanced Options\Set external IP address Set the External IP Address as desired. 6.10 Version handling The version handling menu provides tools to import, export, and restore the autoclave software.
  • Page 62 6.10.2 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 63: Cycle Parameters

    All the autoclave settings will be imported from the USB device with the exception of the screen above. 6.10.3 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 USB device.
  • Page 64 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). For the custom cycles created by duplication, and for the Warm Up cycle, all the options listed in table below are changeable.

  • Page 65: Temperature Sensors

    Sterilization Temperature Heating Sterilization Temperature Sterilization Sterilization Time Cooling (“C” Cool Mode Cool End Temperature Cool Exhaust Rate only) Exhaust Exhaust Mode Dry Time Dry Heat On 1 Dry Heat Off 1 Drying Dry First Stage Time Dry Heat On 2 Dry Heat Off 2 Add Dry Time Ending...

  • Page 66: Displayed Inputs

    Using Up and Down keys, move the cursor around the screen and check the desired radio buttons by pressing Start/Stop. Using Up and Down keys, move the cursor to Save and press Start/Stop. 6.13 Displayed inputs This menu defines 2 (or 3, according to the cycle type) input values to be shown on the display.

  • Page 67: Purge (Generator Models Only)

    Using Up and Down keys, move the cursor to the desired radio button and choose it by pressing Start/Stop. 6.14 Purge (generator models only) There is an option to remove the air from the chamber before sterilization. Saturated steam is introduced into the chamber and it pushes the air out through a valve.
  • Page 68 6.15.1 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 69: Keep Heat

    6.15.4 Pulse A High Pressure This parameter defines the higher pressure value for the A pulse Browse to the following folder: Cycle parameters\Create Pulse\Pulse A High Pressure 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 70: Heating

    This parameter allows you to set two temperatures at which the process will be paused (Keep Heat). Pause duration is set by Temperature 1 (2) stay time parameter. Browse to the following folder: Cycle parameters\Keep Heat\Temperature 1 stay time Note: same parameters are available for temperature 2. Change the parameter as desired.

  • Page 71: Cooling ("C" Models Only)

    6.18.2 Sterilization Time This parameter defines duration of the sterilization stage for the cycle. Browse to the following folder: Cycle parameters\ Sterilization\Sterilization Time Change the parameter as desired. 6.19 Cooling (“C” models only) This menu defines parameters for the cooling stage. 6.19.1 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...

  • Page 72: Exhaust

    6.19.3 Cool Exhaust Rate This parameter defines how quickly the pressure will go down during exhaust after cooling. Browse to the following folder: Cycle parameters\Cool Mode\Cool Exhaust Rate Change the parameter as desired. 6.20 Exhaust This menu defines parameters for the exhaust stage. 6.20.1 Exhaust Mode The Exhaust mode parameter equals: ...
  • Page 73 6.21.1 Dry Time This parameter defines duration of the drying stage for the cycle. Browse to the following folder: Cycle parameters\Drying\Dry Time Change the parameter as desired. Drying stage is divided into two stages. For each stage you can set the total time, on time and off time.

  • Page 74: Ending

    Cycle parameters\Drying\Dry Heat Off 1 Change the parameter as desired. Note: There are Dry heat On 2 and Dry heat Off 2 parameters for the Dry Second Stage of the drying. 6.21.4 Dry First Stage Time This parameter defines duration of the Dry First Stage. The Dry Second Stage time is calculated as Dry Time minus the Dry First Stage Time, that is why there is no Dry Second Stage Time menu.
  • Page 75 6.23.1 F0 mode This parameter checks how long has the load been in sterilization conditions (pressure, temperature) before the sterilization stage actually begins. This data helps preventing damage to the load by excessive exposure to heat and high pressure. Browse to the following folder: Cycle parameters\Global\F0 mode Change the parameter as desired 6.23.2 Check RTC...
  • Page 76 6.23.4 Multiple Cycles Gap This parameter allows you set the time interval between the multiple cycles (see above). Browse to the following folder: Cycle parameters\Global\Multiple Cycles Gap Change the parameter as desired. 6.23.5 Jacket Temperature This parameter defines the temperature of the jacket (for the relevant models only).

  • Page 77: Generator Description

    7. Generator description A built-in steam generator supplies the steam for the sterilization process. The steam generator is an electrically-heated type, equipped with immersion heaters, divided into three-phases. The power consumption of the generator is 9kW. 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 78: Generator Electrical Safety System

    Warning: Only a qualified electrician may perform the electrical connections! The electrical units should not be placed near water sources. When servicing the generator, disconnect all the electrical power supplies to the unit. This is done by switching OFF the main power supply switch, or by un-plugging the electrical power main supply cords.

  • Page 79: The Water Pump For The Steam Generator

    The Water Pump for the Steam Generator The water pump supplies the distilled or mineral-free water to the steam generator. The supply line of the pump is connected to the upper water reservoir filled with distilled or mineral-free water and mounted on side of the autoclave.
  • Page 80 The long electrode which is continuously immersed in the water, acts as a reference and is connected to ground. The medium electrode (LOW level electrode) controls the water heaters. When it stops sensing water, the GICAR controller stops the current to the water heaters. When it senses water, the GICAR controller restores current to the water heaters.

  • Page 81: Maintenance And Replacement Procedures: The Autoclave

    8. Maintenance and Replacement Procedures: the Autoclave Warning! Do not touch door microswitches in case of malfunction! Call Tuttnauer service. 8.1 Preliminary Operations for Each Technician Call In order to maintain efficient service, the technician must perform the following: Inspect and clean if needed, the following: ...

  • Page 82: Replacing The Circuit Breaker

    Every 6 months  Tighten the bolts of the heater bands and the electrical connections of the heaters, valves and connectors in the control box.  Drain the generator and refill with mineral free water. Once a year  Check the grounding continuity. ...

  • Page 83: Replacing The Safety Valve

    Remove four screws connecting the circuit breaker to the panel (3). Note: the (4) must be on 250°. Replace the circuit breaker with a new one and assemble it to the autoclave with the 4 screws (3). Attention: Make sure that a 15A 3ph circuit breaker is installed! Reconnect the electrical wires (1, 2).
  • Page 84 This paragraph refers to the chamber's and the generator's safety valves This paragraph refers to PED and ASME approved safety valves Note: The safety valve is located on the rear of the autoclave. Remove the safety vale cover (2) by pressing both sides of the cover inwards (1) and pulling it out (3) of its seats (slots in the rear wall of the autoclave -4) to reveal the safety valve (5).

  • Page 85: Replacing The Door Gasket

    Description Cat. No. SVL029-0028 Safety marked valve ASME SVL029-0004 Safety valve base CMV100-0004 Washer CMT240-0022 CMT240-0020 8.4 Replacing the door gasket Caution! Before starting, disconnect the instrument from the power source and ensure that there is no pressure in the chamber or the generator.

  • Page 86: Replacing The Door Cover

    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 87 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. 8.5.1 Disassembling the door cover The opening of the door is limited by two stoppers assembled on the door's hinges.
  • Page 88 Unscrew the screws assembling the axis bridge (11) to the door bracket (5). Remove the door cover 8.5.2 Assembling the door cover Assemble door bracket (5) to the door cover (4) with 10 screws (6). Page 86...
  • Page 89 Assemble the axis bridge (10) to the axis seat (7) with a pin (9) and cotter pin (8). Place the door cover (4) on the door (12) so that the axis bridge (11) will cover the door bracket (5) and assemble the door to the axis bridge with screws.
  • Page 90 Lift the spring holder (13) and place the spring holder support P/N CMT387-0148 (14, supplied with the autoclave), as shown in the picture below. Perform this on the right and on the left spring holder. Lift the door and insert the edge of the spring holder (16) into the slot (15).

  • Page 91: Replacing The Printer

    After the edge of the spring holder is in the slot the door cover is attached to the door. At this stage remove the spring holder supports (14). Close the door. With a screwdriver, inserted through the holes in the rear of the door cover (3), fasten the 4 screws of the door stoppers.
  • Page 92 Unscrew 2 screws (1) fastening the control panel. Turn the panel to reveal the internal part and the electrical connectors. Unplug the board connectors (3) and the printer connectors (2). Verify that you know where plug each is connected. The printer is fastened (6) to its seat with two fasteners (5). To release the fasteners, press slightly on the part marked (4) and pull the fattener upward.

  • Page 93: Replacing The Door Micro-Switch

    8.7 Replacing the Door Micro-Switch 1 Warning! Do not touch door micro-switches in case of malfunction! Call Tuttnauer service. Unscrew the 2 screws (1). Unscrew the nut (2) and remove the micro-switch. Release the wires from their connector in the electric box.

  • Page 94: Replacing The Air Filter

    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. Allow the autoclave to cool before removing outer covers.

  • Page 95: Replacing The Locking Motor

    Open back service door. Unscrew and remove the filter (1) from its seat. Replace the filter with a new one, use only an original filter supplied by Tuttnauer. Assemble the filter (1) to its seat. Close left service door. 8.10 Replacing the locking motor...
  • Page 96 Open left service door. Move the sleeve covering the wires connection (8) to reveal the connections and disconnect the wires of the electric motor. Remove cotter pin (6). Remove the pin (5) attaching the motor's rod (4) to the locking arms (7).

  • Page 97: Replacing The Plunger Or Coil Of The 1/4" Solenoid Valve

    8.11 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 98: Replacing The Plunger Or Coil Of The Baccara Solenoid Valve

    8.12 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, coil or generator.

  • Page 99: Replacing The Pressostat 0.2 (Nc)

    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 100: Replacing The Power Supplies, Water Level Board And Relays

    8.15 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 101 The autoclave electric box Description of Items Photo Cat. No. Description Buzzer BUZZER PIEZO, ELE035-0192 CONTINUOUS, 85dB@30cm/3- 28VDC ELE035-0129 Power Supply 24VDC (4.2A) Page 99...
  • Page 102 ELE035-0144 Power Supply 24VDC (1A) CTP201-0273 Miniature Relay (orange) 24VDC CTP201-0271 Relay Socket Terminal, Feed-Through, 2- THE039-0091 Conductor, Fuse Disconnect 1 1/4X1/4, 4mm² Transformer TDB-100T 230/115- ELE035-0092 6/12VAC Fan, 24VDC, Dia. 80mmx20mm, CTP201-0318 34.6CFM Page 100...
  • Page 103 The generator electric box Description of Items No. Photo Cat. No. Description Level regulator, 2 regulation units, CTP201-0198 230V, 2DRLH, GICAR THE005-0040 Thermostat, Safety, 300°C ,16A , 230V Trip Coil FAZ-XAA-NA110-415VAC, ELE034-0056 Moeller Page 101...
  • Page 104 Circuit Breaker, 1 pole, 4A, FAZ-C4, ELE034-0017 Moeller ELE034-0041 Circuit Breaker, 3 pole, 16A Page 102...

  • Page 105: Maintenance And Replacement Procedures: The Generator

    9. Maintenance and Replacement Procedures: the Generator 9.1 Access to Generator Unscrew the screws (1) fastening the generator compartment cover and remove it. Turn the electric power off and release the steam pressure from the autoclave and the steam generator. 9.2 Draining the generator Caution! Before starting, be sure that the electric cord is disconnected from the...

  • Page 106: Cleaning And Replacing The Water Level Electrodes

    Close the service door. 9.3 Cleaning and Replacing the Water Level Electrodes Caution! Before starting: Make sure that the electric cord is disconnected and that there is no pressure in the autoclave. Make sure there is no pressure in the generator. If there is, open the right service door and reduce the generator pressure by opening the drain valve.
  • Page 107 Water Reference Heater Page 105...

  • Page 108: Replacing The Heating Elements

    9.4 Replacing the Heating Elements Caution! Before starting: Make sure that the electric cord is disconnected and that there is no pressure in the autoclave. Make sure there is no pressure in the generator. If there is, open the left service door and reduce the generator pressure by opening the drain valve.
  • Page 109 Make sure there is no pressure in the generator. If there is, open the left service door and reduce the generator pressure by opening the drain valve. Warning! Do not exceed the recommended pressure of the gauge glass. Caution! Do not subject gauge glass to bending or torsional stresses. 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 110: Replacing The Generator Thermostat

    Description Cat. No. Brass Washer CMT254-0136 Silicon gasket GAS082-0005 Hex Domed Cap (Acorn) Nut NUT192-0205 Protecting Bar GEN221-0060 Water level glass tube SRV000-0128 9.6 Replacing the Generator Thermostat Caution! Before starting: Make sure that the electric cord is disconnected and that there is no pressure in the autoclave.
  • Page 111 If the autoclave is operated according to instructions, and the thermostat cuts out again, replace the thermostat as follows: Disconnect the wires (mark them to connect in the correct order). Remove the sensor of the faulty cut-off (1) from its seat in the generator (2).

  • Page 112: The Water Pump Replacement

    Release pressure on the outlet side of the pump before doing any maintenance work. Check the pump for any sign of damage. If the pump has any indication of failure, contact Tuttnauer for a complete motor assembly. Proceed as follows to replace the pump. Open the generator service door.
  • Page 113 Caution! Before starting: Make sure that the electric cord is disconnected and that there is no pressure in the autoclave. Make sure there is no pressure in the generator. If there is, open the right service door and reduce the generator pressure by opening the drain valve.

  • Page 114: Troubleshooting

    10. Troubleshooting Warning! Do not touch door microswitches in case of malfunction! Call Tuttnauer service. This troubleshooting chart enables the user to solve minor malfunctions, prior to contacting our service department. Only technical personnel having proper qualifications and holding technical documentation (including a technician manual) and adequate information are authorized to service the apparatus.
  • Page 115 Possible causes check-ups Symptoms Corrections and tests Circuit breakers Turn off or replace switched off or the circuit breakers. damaged. Contactor controlling Check the cause and the heat up current is replace contactor. damaged. Control system Replace the GICAR trouble. 2.10 Solenoid or 2.10...
  • Page 116 Possible causes check-ups Symptoms Corrections and tests steam supply line. as shown in par. 2. Control system Replace the control trouble. boards. Manual steam feed Open the manual valve is closed. valve. 5. Pre-vacuum Low pressure at the Check steam phase steam supply line.
  • Page 117 9. The air inlet Air inlet valve clogged Repair or replace air does not work. or damaged. valve. Air filter clogged. Replace air filter. 10.1 Incomplete removal 10.1 See trouble related to Unsatisfactory of air pockets. vacuum system par. results of 2 and 4.
  • Page 118 sliding doors) 13.3 The pressure to 13.3 Fix or replace the gasket pneumatic pneumatic valve. valve blocked or damaged. 13.4 The solenoid or 13.4 Repair or replace the pneumatic valves, defective valve. which control the pressure or vacuum to gasket stuck or damaged.

  • Page 119: Steam Generator Troubleshooting

    Possible causes check-ups Symptoms Corrections and tests unsuitable. Ensure the appropriate type of paper is used. 15.6 Flat cable connection 15.6 Plug in connection or between control replace it. board and printer is not plugged in correctly. 15.7 Printer damaged. 15.7 Replace the printer.
  • Page 120 into the solenoid valve does solenoid contacts or, generat not open. repair/replace the valve. Check for short The circuit breaker in circuits, or circuit the water pump motor breaker is defective. circuit trips OFF. Replace the circuit The GICAR water breaker, or fix short level controller or the circuit.
  • Page 121 Steam The pressure switch is Set the pressure pressur faulty or set switch correctly or e goes incorrectly. replace if faulty. Replace the heater beyond contactor. The heater contactor is the set stuck. control point. The steam pressure is Check cause and safety higher than the remedy it, See section...

  • Page 122: List Of Spare Parts

    11. List of Spare Parts Part Number Description CMT387-0099 Basket Seat, Perforated, 38xx MLV/ELV, St.St. GAS084-0025 Tube, White, Reinforced PVC, 1/2"x2M, 50C, RHWW- HAN071-0005 Handle, Carrying, for side wall Horizontal Autoclave GAS084-0031 Tube, Black, Reinforced Rubber,2M long,Nut 1/2" BSP,Free next side POL065-0085 DOOR COVER 3870-D-GENERAL ASSY.
  • Page 123 MAMAB FIT100-0226 Nut for Sleeve, Tube 1/4, Thread 7/16-24, Brass ELE032-0048 Harness, Command, 3870ELV(C)(PV)& G -D SOL026-0077 Connector, 2 Contacts, 24V, Black, DIN43650, KA132L34B9, CNE ELC387-0118 Control Panel, Bacsoft Control System,(W/printer)3870EL(V) -Assy. CPN064-0031 Keyboard, EZ 9"&11", EZ/3870-D & Hor.-D CTP200-0138 Board, I/O Extension, Bacsoft CTP200-0140 Board, Main Control, Bacsoft...
  • Page 124 ELE035-0129 PSU,DIN Rail,24VDC,4.2A,100W ELE035-0144 Power Supply, 24VDC, 1A ELE035-0144 Power Supply, 24VDC, 1A NUT192-0217 Hex Nut, 8-32UNC, Brass, Plain NUT192-0230 Nut,Clip-On,U-Style,4.8x20x13,0.7 thick.,Spring steel,Cadmium plated NUT193-0291 Serrated Lock Washer External Teeth,M4(5/32),Steel,Zinc Pl.,DIN6798A THE039-0120 Push-In Type Jumpers Bar 2-Pole Nominal CTP201-0318 Fan, 24VDC, Dia. 80mmx20mm, 34.6CFM ELE035-0192 BUZZER, PIEZO, CONTINUOUS, 85dB@30cm/3- 28VDC...
  • Page 125 ELE039-1062 Male Connector,2 Pole,5mm Pin Spacing with Cage Clamp Connection THE039-0099 Terminal, Feed-Through, 3-Conductor, 2.5 mm², Gray THE039-0100 Terminal, Feed-Through, 3-Conductor, 2.5 mm², Red THE005-0040 Thermostat, Safety, 300°C ,16A , 230V CMT387-0022 Holding bracket - 3150-3870ELV FIT100-0216 Sleeve, Tube 1/4, Brass, 60C-4, Parker FIT100-0226 Nut for Sleeve, Tube 1/4, Thread 7/16-24, Brass NUT192-0192...
  • Page 126 FC2X WHE070-0015 Leg, PVC ,Bolt Type 3/8", 60mm PAN387-0025 Cover, Service, Front, 3870ELV-C COV411-0010 Shield, Safety Valve, ELV-D PAN387-0035 Door, Service, Side, 3870ELV-C GEN220-0063 Electrode, water level, 1/4" NPT, 175mm HEA016-0049 Heating Element, Immersion, Threaded,230V,2", 3x3000W, St.St.- UL HEA016-0049 Heating Element, Immersion, Threaded,230V,2", 3x3000W, St.St.- UL GAS082-0087 Gasket, 76x59.5x3 For Heating Element Vertical...
  • Page 127 SOL026-0050 Valve, Solenoid, 2/2 way, 1/4"BSPx4.5, NC, 230VAC, THE005-0039 Switch, Pressure,N.O. 1/4" BSP,Set 0.2 Bar. VLV170-0055 Valve, Manual Ball, Mini, 1/4" NPT FIT100-0081 Elbow, 90, Equal, F & M, 1/4"NPT, Brass FIT100-0084 Nipple, Parallel, 1/2*1/4 NPT, Brass, S11420, Sistem Pneumatica FIT100-0216 Sleeve, Tube 1/4, Brass, 60C-4, Parker FIT100-0226...
  • Page 128 FIT100-0809 Elbow Connection O-RING -1/4" BSP M / Tube(8*6) FIT100-0812 Adaptor, Elbow, Orienting, Male 1/4"", Tube 1/4 FIT100-0814 Straight Male O-RING - 1/4 M / Tube 1/4 FIT100-0818 1/4"BSP T section O-RING - F/F/M ELC258-0016 Sensor, Temperature, PT100, 5x60, 3 Wires, Assy. (For D line) THE003-0013 Sensor, Temperature, PT100, 5X70, TUT-001,...
  • Page 129 GAU029-0062 Pressure Regulator, Water, In Line with Strainer, 1/4"BSP, 0.5 Bar NUT192-0192 Hex Nut, M5X4, Stainless Steel A2, DIN934 NUT192-0193 Hex Nut, M6X5, Stainless Steel A2, DIN934 NUT193-0271 Plain Washer Without Chamfer, M5 (3/16), Stainless Steel A2, DIN125 NUT193-0283 Plain Washer, 1.2X7.45X16.1, Stainless Steel A2 NUT193-0317 Spring Lock Washers With Square Ends, 1/4, St.

  • Page 130: Water Outlet Strainer

    11.1 Water Outlet Strainer Strainer Strainer Gasket element Housing Description Cat. No. Cap for ¼” strainer FIL175-0027 Strainer element FIL175-0046 Teflon gasket 4 mm GAS082-0008 Strainer Housing + Cap FIL175-0051 Page 128...

  • Page 131: Pressure Vs Temperature For Saturated Steam

    12. Pressure vs Temperature for Saturated Steam °C °F psig psia °C °F InHg psia 104.3 117.9 1.18 219.7 17.1 45.8 0.10 114.5 2.95 104.4 118.6 1.18 219.9 17.2 54.1 0.15 129.3 4.44 104.5 118.6 1.19 220.1 17.2 60.1 0.20 140.2 5.90 104.6...
  • Page 132 °C °F psig psia °C °F InHg psia 106.9 129.0 1.29 224.4 18.7 101.5 106.9 1.07 214.7 15.5 107.0 129.6 1.29 224.6 18.8 101.6 107.3 1.07 214.9 15.6 107.1 129.9 1.30 224.8 18.9 101.7 107.7 1.08 215.1 15.6 107.2 130.4 1.30 225.0 18.9...
  • Page 133 °C °F psig psia °C °F InHg psia 115.3 170.8 1.71 239.5 10.0 24.7 109.8 142.4 1.42 229.6 20.6 115.4 171.3 1.71 239.7 10.1 24.8 109.9 142.9 1.43 229.8 20.7 115.5 171.8 1.72 239.9 10.2 24.9 110.0 143.3 1.43 230.0 20.8 115.6 172.4...
  • Page 134 °C °F psig psia °C °F InHg psia 117.7 184.5 1.85 243.9 12.1 26.8 112.2 154.3 1.54 234.0 22.4 117.8 185.1 1.85 244.0 12.1 26.8 112.3 154.8 1.55 234.1 22.4 117.9 185.7 1.86 244.2 12.2 26.9 112.4 155.3 1.55 234.3 22.5 118.0 186.3...
  • Page 135 °C °F psig psia °C °F InHg psia 120.1 199.2 1.99 248.2 14.2 28.9 114.6 167.0 1.67 238.3 24.2 120.2 199.8 2.00 248.4 14.3 29.0 114.7 167.5 1.67 238.5 24.3 120.3 200.5 2.00 248.5 14.4 29.1 114.8 168.0 1.68 238.6 24.4 120.4 201.1...
  • Page 136 °C °F psig psia °C °F InHg psia 127.8 252.9 2.53 262.0 22.0 36.7 122.5 214.8 2.15 252.5 16.6 31.3 127.9 253.7 2.54 262.2 22.1 36.8 122.6 215.2 2.16 252.7 16.7 31.4 128.0 254.5 2.54 262.4 22.2 36.9 122.7 216.2 2.16 252.9 16.8...
  • Page 137 °C °F psig psia °C °F InHg psia 130.2 271.9 2.72 266.4 24.7 39.4 124.9 231.5 2.31 256.8 18.9 33.6 130.3 272.7 2.73 266.5 24.8 39.5 125.0 232.2 2.32 257.0 19.0 33.7 130.4 273.5 2.73 266.7 25.0 39.7 125.1 232.9 2.33 257.2 19.1...
  • Page 138 136.4 326.2 3.26 277.5 32.8 47.3 132.4 290.2 2.90 270.3 27.4 42.1 136.5 327.1 3.27 277.7 33.0 47.4 132.5 291.1 2.91 270.5 27.5 42.2 136.6 328.1 3.28 277.9 33.1 47.6 132.6 291.9 2.92 270.7 27.6 42.3 136.7 329.0 3.29 278.1 33.2 47.7 132.7 292.8 2.93 270.9 27.8 42.5 136.8 330.0 3.30 278.2 33.3 47.9 132.8 293.6 2.94 271.0 27.9 42.6 136.9 330.9 3.31 278.4 33.3 48.0 132.9 294.5 2.94 271.2 28.0 42.7 137.0 331.9 3.32 278.6 33.4 48.1 133.0 295.4 2.95 271.4 28.1 42.8...
  • Page 139 138.9 350.4 3.50 282.0 36.1 50.8 134.9 312.3 3.12 274.8 30.6 45.3 139.0 351.4 3.51 282.2 36.3 51.0 135.0 313.2 3.13 275.0 30.7 45.4 139.1 352.4 3.52 282.4 36.4 51.1 135.1 314.1 3.14 275.2 31.1 45.6 Legend: psia ─ absolute pressure in psi Psig ─...

  • Page 140: 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 141 53-2. Vacuum - from door 2 seal Drain – from reservoir Drain – from jacket overflow Drain – from vacuum pump / ejector Drain – from chamber Drain – from cooler DRAIN Drain – from sanitary filter Drain – from steam generator Drain –...

  • Page 142: Drawings

    14. Drawings 14.1 Piping Drawing – Model 3840/3850/70 ELVCG-D Page 140...

  • Page 143: Piping Drawing - Model 3840/3850/70 Elvcpvg-D

    14.2 Piping Drawing – Model 3840/3850/70 ELVCPVG-D Page 141...

  • Page 144: Piping Drawing - Model 3840/3850/70 Elvcpvgbh-D

    14.3 Piping Drawing – Model 3840/3850/70 ELVCPVGBH-D Page 142...

  • Page 145: Electrical Drawing For The Autoclave 3840-50/3870 Elv(C)(Pv)G 380V

    14.4 Electrical Drawing for The Autoclave 3840-50/3870 ELV(C)(PV)G 380V Page 143...
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  • Page 153: Electrical Wiring Diagram: The Generator

    14.5 Electrical Wiring Diagram: The Generator Legend: 1. HEATERS = 400V /9000W 3. CB1 = CIRCUIT BREAKER: FAZ-C 16/3 2. KM1 = CONTATOR: DILM12-10 4. QS1 = PANEL SWITCH: N/A Page 151...

  • Page 154: Generator Control Electrical Cascade Diagram

    14.6 Generator Control Electrical Cascade Diagram Page 152...

This manual is also suitable for:

3850 elvg-d3870 elvg-d

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