Tuttnauer 2301006 Operation & Maintenance Manual Download Page 14

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Page 9 of 117 pages

Summary of Contents for 2301006

Page 1: ...o Steam Generator and Vertical Sliding Door model 6690 STS 1V S N 2301006 2301007 2301011 2301012 2301013 2301014 2301015 2301016 2301017 2301018 Cat No MAN205 0211 002 Rev C Manufactured by Tuttnauer...

Page 2: ......

Page 3: ...rol System 13 15 3 Sterilization Programs 16 39 4 Control and Monitoring Control Panel CAT 2007 40 4 1 Description of panel CAT 2007 41 4 1 1 Keypad 41 42 4 1 2 Display 43 44 4 2 Description of Displa...

Page 4: ...nter 10 1 Printer Operation 75 76 10 2 Printer Handling 77 11 Maintenance of the Autoclave 11 1 Preventive and Periodical Maintenance 78 SERVICE INSTRUCTIONS 11 2 Safety Tests after Repair 80 11 3 Tro...

Page 5: ...essure and Temperature Table for Saturated Steam 99 Drawings The Pneumatic Control System Drawing 9 Vertical Sliding Door 100 Vertical Door Locking Mechanism 101 Piping drawing 102 Electric drawing fo...

Page 6: ...instructions in paragraph 11 1 Preventive and Periodical Maintenance Our obligation is limited to replacing the instrument or parts after our examination if within one year after the date of shipment...

Page 7: ...uments gravity four for wrapped instruments and packages and four for liquids Two test programs are also available the VACUUM TEST for checking the tightness of the chamber and piping system and the B...

Page 8: ...PC control unit enables the complete control of the autoclave through the PC including program selection starting and stopping the cycle setting of parameters and the real time clock data and time of...

Page 9: ...lue 72 215 TDS of CaCO3 Recommended temperature 59 F 50 80 PSI 12 5 GPM Peak 275 GPH Avg Compressed air requirements Pressure 90 110 PSI 3 5 SCFM 3 8 thread connection Electrical data Voltage 1 ph 115...

Page 10: ...relief valve blows off at a pressure of 40 psi to prevent build up of overpressure in case of control failure Only mineral free water or distilled water will be used for operation of the generator See...

Page 11: ...e door Fast exhaust to drain valve 73 evacuates the steam from the chamber to drain at a fast rate until pressure goes down to zero in the prevacuum and post sterilization phases Condense valve 74 eva...

Page 12: ...es Besides the pilot solenoid valves which control the air operated valves the following solenoid valves have direct action as described below Close door valve 39 is a solenoid valve which transmits c...

Page 13: ...a manifold branch base through which all the solenoids are connected to the compressed air supply At the output side of the manifold branch a pressure regulator at 3 bars sets the compressed air As lo...

Page 14: ...Page 9 of 117 pages...

Page 15: ...ride 3 mg l Phosphate 0 5 mg l Conductivity 50 s cm pH 6 5 to 8 Appearance colorless clean without sediment Hardness 0 1 mmol l Compliance with the above data should be tested in accordance with ackno...

Page 16: ...he RO cannot normally attain the degree of purity possible with the DI methods it is more than adequate for the feed water intended for clean steam generators Moreover the RO has several advantages 1...

Page 17: ...and regulations in force and International EN 61010 1 electrical safety standards and certified by the competent authorities Description of the Electrical Equipment The command signal for the contact...

Page 18: ...itches pressure cut off switches cut off switches for water level The input voltage will not exceed 24VDC The input must be protected from high voltages by means of an Opto coupler Digital Outputs Dig...

Page 19: ...maximum 1 from the range i e 5kPa Calibration of the pressure circuit needs a special code Measuring the pressure of a gasket The measurement range is 0 400 kPa absolute The resolution measurement and...

Page 20: ...computer RS232 1 Serial Port connected to an internal PC computer that will work as an activating panel RS232 If it will be necessary to convert some functions or to reprogram or to reload the softwar...

Page 21: ...mins Performance description Residual air is displaced due to 3 vacuum pulses down to 25 kPa and 2 steam pulses up to 199 kPa The third vacuum pulse is followed with introducing saturated controlled...

Page 22: ...ose door Ejector Buzzer 13 Cool drain 15 Water to ejector 43 Air inlet 73 Fast exh 74 Slow exh 75 Vacuum 97 Steam to jacket 93 Steam to chamber 273 F 310kPa 250 F 210kPa 199kPa 230 F 115kPa 100kPa 50k...

Page 23: ...a way that the sterilization temperature will not drop below the required temperature neither will increase by more than 37 4 F The saturated steam conditions are controlled in such a way that the fl...

Page 24: ...se door Ejector Buzzer 13 Cool drain 15 Water to ejector 43 Air inlet 73 Fast exh 74 Slow exh 75 Vacuum 97 Steam to jacket 93 Steam to chamber 273 F 310kPa 250 F 210kPa 199 kPa 230 F 115kPa 100kPa 50k...

Page 25: ...is controlled in such a way that the sterilization temperature will not drop below the required temperature neither will increase by more than 37 4 F The saturated steam conditions are controlled in s...

Page 26: ...se door Ejector Buzzer 13 Cool drain 15 Water to ejector 43 Air inlet 73 Fast exh 74 Slow exh 75 Vacuum 97 Steam to jacket 93 Steam to chamber 273 F 310kPa 270 274 F 210kPa 199 kPa 230 F 115kPa 100kPa...

Page 27: ...ot drop below the required temperature neither increase by more than 37 4 F The saturated steam conditions are controlled in a way that the fluctuation of pressure does not allow a drop below 1kPa nei...

Page 28: ...Open door Close door Ejector Buzzer 13 Cool drain 15 Water to ejector 43 Air inlet 73 Fast exh 74 Slow exh 75 Vacuum 92 Steam to jacket 93 Steam to chamber 273 F 310kPa 270 F 210kPa 199kPa 230 F 115kP...

Page 29: ...drop below the required temperature neither will increase by more than 37 4 F The saturated steam conditions are controlled in such a way that the fluctuation of pressure does not allow a drop below...

Page 30: ...t door Close front door Ejector Buzzer 13 Cool drain 15 Water to ejector 43 Air inlet 73 Fast exh 74 Slow exh 75 Vacuum 97 Steam to jacket 93 Steam to chamber 273 F 310kPa 270 F 210kPa 199 kPa 230 F 1...

Page 31: ...l not drop below the required temperature neither will increase by more than 37 4 F The saturated steam conditions are controlled in such a way that the fluctuation of pressure does not allow a drop b...

Page 32: ...nt door Close front door Ejector Buzzer 13 Cool drain 15 Water to ejector 43 Air inlet 73 Fast exh 74 Slow exh 75 Vacuum 97 Steam to jacket 93 Steam to chamber 273 F 310kPa 274 F 210kPa 199kPa 230 F 1...

Page 33: ...w the required temperature neither will increase by more than 37 4 F The saturated steam conditions are controlled in such a way that the fluctuation of pressure does not allow a drop below 1kPa neith...

Page 34: ...t door Close front door Ejector Buzzer 13 Cool drain 15 Water to ejector 43 Air inlet 73 Fast exh 74 Slow exh 75 Vacuum 97 Steam to jacket 93 Steam to chamber 273 F 310kPa 270 F 210kPa 199 kPa 230 F 1...

Page 35: ...controlled in such a way that the sterilization temperature will not drop below the required temperature neither will increase by more than 37 4 F The saturated steam conditions are controlled in suc...

Page 36: ...Close front door Ejector Buzzer 13 Cool drain 15 Water to ejector 43 Air inlet 73 Fast exh 74 Slow exh 75 Vacuum 97 Steam to jacket 93 Steam to chamber 273 F 310kPa 250 F 210kPa 199 kPa 230 F 115kPa...

Page 37: ...s controlled in such a way that the sterilization temperature will not drop below the required temperature neither will increase by more than 37 4 F The saturated steam conditions are controlled in su...

Page 38: ...Close front door Ejector Buzzer 13 Cool drain 15 Water to ejector 43 Air inlet 73 Fast exh 74 Slow exh 75 Vacuum 97 Steam to jacket 93 Steam to chamber 273 F 310kPa 250 F 210kPa 199 kPa 230 F 115kPa 1...

Page 39: ...d in such a way that the sterilization temperature will not drop below the required temperature neither will increase by more than 37 4 F The saturated steam conditions are controlled in such a way th...

Page 40: ...door Close door Ejector Buzzer 13 Cool drain 15 Water to ejector 43 Air inlet 73 Fast exh 74 Slow exh 75 Vacuum 97 Steam to jacket 93 Steam to chamber 273 F 310kPa 250 F 210kPa 199 kPa 221 F 115kPa 1...

Page 41: ...ired temperature neither will increase by more than 37 4 F The saturated steam conditions are controlled in such a way that the fluctuation of pressure does not allow a drop below1kPa neither an incre...

Page 42: ...door Close door Ejector Buzzer 13 Cool drain 15 Water to ejector 43 Air inlet 73 Fast exh 74 Slow exh 75 Vacuum 97 Steam to jacket 93 Steam to chamber 273 F 310kPa 274 F 210kPa 199 kPa 230 F 115kPa 10...

Page 43: ...This test is performed in vacuum phase Performance description Vacuum is built up in the chamber down to 10kPa At this stage all valves and motors are shut A period of 5 minutes is counted to enable...

Page 44: ...ber Open door Close door Ejector Buzzer 13 Cool drain 15 Water to ejector 43 Air inlet 73 Fast exh 74 Slow exh 75 Vacuum 97 Steam to jacket 93 Steam to chamber 273 F 310kPa 250 F 210kPa 199 kPa 230 F...

Page 45: ...Page 40 of 117 pages 4 CONTROL AND MONITORING Control Panel CAT 2007...

Page 46: ...l be listed on the display above the keypad 10 Digit keypads These keypads are used for 2 purposes In normal working conditions the program option is used pressing on the number keypad for example no...

Page 47: ...switches off the FAIL light RUN FAIL LED s The operation panel contains 2 small LED s are located on the top left corner The RUN LED green lights when the autoclave is in process When the system has b...

Page 48: ...e is ready to work READY When a process ends correctly END When a program ends incorrectly FAIL The names of the stages follow Vacuum Exh Exhaust Heat Dry Ster sterilization Test Following are the 14...

Page 49: ...ere are three keypads without symbols or names These keypads receive their commands by the name that appears above them in the 4th row of the display During a cycle the fourth row is used to display t...

Page 50: ...e is aborted if the temperature drops for more than 5 secs below the required sterilization temperature 09 High Temp Message is displayed fail indicator lights and program is aborted If the temperatur...

Page 51: ...vel and in case it s too high closes all the valves and the FAIL indicator lights Informative Messages Calibration This message appears automatically on panel 2 during calibration Closing Door Wait Wh...

Page 52: ...cycles can be started when all the relevant conditions are fulfilled If the system is ready the display appears as follows If the system is not ready it will not allow you to start the cycle If for e...

Page 53: ...ram number is 10 or above For example to chose program 12 number 1 must be pressed and within 2 seconds number 2 must be pressed Show Parameters After selecting the cycle pressing the SHOW command key...

Page 54: ...me only one output is turned on The output passes to ON for a maximum time of 15 seconds or until the UP keypad is pressed The command begins from output number 1 until 24 2 Testing of all the digital...

Page 55: ...ng the three times and then the number 4 When a value is to be entered the right command keypad is Enter If the value is entered via the digit keypad after the final digit is entered the system automa...

Page 56: ...is underlined Press the UP DN key to change this value Press ENTER the right command key to move on to the minute value Continue the process until the time is correct If no changes are to be made pre...

Page 57: ...e The atmospheric pressure at Sea Level is 100kPa For every 100m above sea level the atmospheric pressure drops 1kPa and for every 100m below sea level the atmospheric pressure increases 1kPa If press...

Page 58: ...les with Ster Temp in the range of 215 F 273 F especially used in Programs 9 12 F O 0 unable F O 1 total heating time total cycle time cooling time F O 2 compensates the difference between heating tim...

Page 59: ...perature for the process Entry code 1 or 11 Resolution 34 F Minimum value 221 F Maximum value 280 F STE Time Required sterilization time for the process Entry code 1 or 11 Resolution 1 minute Minimum...

Page 60: ...alue 5 VacDip1 Vacuum value in the first pulse Defines the vacuum value in pulse no 1 of the prevacuum stage Entry code 11 Resolution 1 kPa Minimum value 1 kPa Maximum value 75 kPa VacDip2 Vacuum valu...

Page 61: ...ket control For example When the desired temperature is 273 F the maximum temperature maintained in the jacket will be adjusted to a temperature of 137 C i e 332kPa When this pressure is not enough it...

Page 62: ...1 min Minimum value min Maximum value 10 min This is the final parameter under Code 11 After pressing ENTER the display will return to the ST BY screen Dry Vac Dry Vac 0 Vacuum pump works continuousl...

Page 63: ...one in the chamber and one in drain control output Selections 1 Sensor on the condense line x 2 dual 2 2 Sensor in the chamber 1 3 Sensor for drain control 5 If sensor number 2 is not connected faulty...

Page 64: ...hes water the value will be small from 80 down to 0 when the water is high in electric molecules When the electrode is in the air not touching water the value will be higher than 80 up to 99 This elec...

Page 65: ...ress on UP to move to the next stage or wait 15 seconds and it will do so automatically The next screen to appear refers to the digital inputs As with the digital outputs it will progress to the next...

Page 66: ...c Door During the process of opening an automatic door the message OPENING DOOR WAIT will appear in the 3rd row Closing an Automatic Door During the process of closing an automatic door the message CL...

Page 67: ...s to the Heat stage the steam enters the system in place of PUMP TO 25K it will display HEAT TO 160K When the cycle then passes to the Exhaust stage in place of HEAT TO 160K it will display EXH TO 100...

Page 68: ...n be turned off at the power switch Turn on the power again whilst at the same time pressing the STOP keypad until you hear a long buzz After the Loading screen the screen lights with the message belo...

Page 69: ...the system through programming or through the autoclave In this chapter we shall describe the calibration of temperature and pressure through the autoclave the programming calibration procedure is alt...

Page 70: ...of these keys takes you to the next screen The values in all the following screens can only be changed via the UP DN keypads Once the correct value appears press Enter and the system will progress to...

Page 71: ...y only After F3 is pressed when it is on the last value it moves on to the next screen Pressing the middle command key F2 reads the value of the sensor Pressing STOP will stop the cycle 5 1 6 Jkt Pres...

Page 72: ...which is accurate Considering the above example setting data can be done as follows Upper Row A 140 F R 141 F A 266 F R 266 F The system calibrates the new offset and gain and loads them into the non...

Page 73: ...emove all the bolts which tighten the control panel with the autoclave panel 2 3 2 Remove the bolts that tighten the control base to the autoclave base 1 3 Disconnect the multi pins connector mounted...

Page 74: ...ray should be lined with a towel or paperwrap before placing the instrument There should be no direct contact between the carbon steel and the stainless steel trays 5 All instruments must be sterilize...

Page 75: ...sterilization and drying programmes Leave space between the packs or wrapped instruments to allow complete removal of air pockets in the conditioning stage and for free circulation of steam in the he...

Page 76: ...ir changes hour Do not use the autoclave in presence of dangerous gases and vapors Utilities Connect the autoclave to the utility supplies as follows Air Connect the air connector on the autoclave to...

Page 77: ...ation the following preparation and checks should be followed Check the water and drain inlets are connected correctly to the utilities and the manual taps on the external lines and the autoclave pipi...

Page 78: ...the maintenance technician by setting the locking key in pos OPEN and entering a code 7 Close the door by pressing the F3 function key when the word CLOSE appears in the lower row of the screen above...

Page 79: ...Page 74 of 117 pages Control Panel Assembly...

Page 80: ...essure Sterilization temperature Sterilization time Summary of performed cycle and identification hints When the sterilization cycle begins the printer starts printing the above data After the prelimi...

Page 81: ...and pressure during the heating stage H02 00 116 2 C 217 3k The time temperature and pressure during the heating stage H03 00 080 6 C 023 1k The time temperature and pressure during the heating stage...

Page 82: ...m the print head insert it in the paper cutter the slot in the front panel and reassemble the front panel on the unit The paper roll is set inside the unit and the printer is ready for use NOTE If the...

Page 83: ...it reaches the working pressure 10 This verifies that the safety valve operates as required and the valve s seat is kept free of mineral deposits 3 months Tech 1 Clean water strainers on pipelines wh...

Page 84: ...Page 79 of 117 pages SERVICE INSTRUCTIONS...

Page 85: ...e testing instrument should be 500V and the test should be performed using the Megger The insulation resistance should be at least 2 M The test is successful if there was no leakage 2 Protective Earth...

Page 86: ...rode dirty or rusted 2 5 Clean or replace the electrode 2 6 Contactor controlling the heat up current is damaged 2 6 Check the cause and replace contactor 2 7 Control system trouble 2 7 Replace boards...

Page 87: ...aust piping 4 5 Check and tighten fitting joints replace defective packing 4 6 Steam inlet valve blocked or damaged 4 6 Fix or replace the steam valve No steam inlet or low steam pressure 4 7 Low pres...

Page 88: ...ontrol system trouble 7 3 Replace control boards 8 Drying stage does not work 8 1 Trouble with the vacuum system 8 1 See par 2 and 4 8 2 Steam valve leaks 8 2 Repair or replace steam valve 8 3 Control...

Page 89: ...are well plugged in 12 1 Plug in firmly the MOLEX connectors 12 2 Power supplies out of order 12 2 Fix or replace the power supply 12 3 Control boards or keyboard 12 3 Replace defective board of micr...

Page 90: ...amaged 14 3 Fix or replace the pneumatic valve 14 4 Solenoid valves pressure or vacuum to gasket blocked or damaged 14 4 Repair or replace the solenoid valve 14 5 Control system trouble 14 5 Replace t...

Page 91: ...mp operating on wrong voltage 2 7 Pump housing damaged cracks 2 1 Fix water supply 2 2 Clean inlet strainer 2 3 Replace piping 2 4 Straighten or replace tube 2 5 Clean valves 2 6 Use right voltage 2 7...

Page 92: ...tch regulates the steam pressure output of the generator It is factory regulated but in case this regulation is not accurate the following steps should be taken 1 Turn pressure switch knob clockwise t...

Page 93: ...et pressure The transducer type IMT 3296 is a membrane pressure sensor and electronic measuring circuit having the following specifications Pressure gauge 0 4bar abs Output span current 4 20mA Supply...

Page 94: ...nerator 2 Disconnect the wire from the electrodes connections 3 Open the nuts that tighten the electrodes 4 Insert a new electrode and tighten the fixing bolt to avoid leakage 5 Reconnect the wires to...

Page 95: ...es the minimum level necessary to ensure a safe operation of the heaters The steam output pressure is regulated by the pressure switch connected to the G PROTEC V1 electronic board which switches the...

Page 96: ...n Minimum commutator diameter is 850 in 21 5 mm 115 23OVAC Check armature windings for open shorts internal ground and commutator connections The windings should not be overheated black in color or ha...

Page 97: ...que to 12 18 m lbs 8 Perform Hi Pot Test as follows 1 The system conductors must be shorted together and all switches must be turned on 2 Hi pot voltage is applied between the shorted conductors and a...

Page 98: ...r remove oil according to the following instructions 11 10 2 Adjusting Oil Quantity 1 When the door is in open position disconnect the compressed air supply to the autoclave 1 2 Add oil through the oi...

Page 99: ...Page 94 of 117 pages 11 11 Dismantling the Cabinets Side Panels Push the side cover upward and pull out A...

Page 100: ...091 Horan R5 board R ELE 034 0018 Circuit Breaker 6A R ELE 035 0012 Main rocker switch R ELE 036 0003 M Sw Crouzet FIL 175 0014 Strainer 1 FIL 175 0023 Strainer 1 2 Stainless Steel FIL 175 0035 Strain...

Page 101: ...T200 THE 006 0006 Pressure transducer 0 4 bar abs IMT 3296 THE 007 0001 Low Water Level Switch VLV 170 0001 Manual valve 1 2 VLV 170 0002 Manual valve 3 4 VLV 170 0016 Valve set for water level tube V...

Page 102: ...cool heat exchanger 13 Feed water cool fast exhaust 14 Feed water to reservoir 15 feed water to vacuum pump ejector 16 Water outlet 17 Shut 18 Feed water to air detector 2 MINERAL FREE WATER 21 Miner...

Page 103: ...ervoir 72 Exhaust to drain 73 Fast exhaust 74 Slow exhaust 75 Exhaust to ejector to vacuum pump 76 Exhaust from heat exchanger 77 Exhaust from steam generator 78 Exhaust through heat exchanger pre vac...

Page 104: ...30 1 273 9 307 8 134 4 45 0 30 3 274 1 308 7 134 5 45 1 30 4 274 3 309 6 134 6 45 2 30 5 274 5 310 5 134 7 45 4 30 7 274 6 311 4 134 8 45 5 30 8 274 8 312 4 134 9 45 6 30 9 275 0 313 3 135 0 45 8 31 1...

Page 105: ...VERTICAL SLIDING DOOR Page 100 of 117 pages...

Page 106: ...Page 101 of 117 pages...

Page 107: ...Page 102 of 117 pages...

Page 108: ...OUTPUT24 PRESS DOOR1 SEAL INPUT3 HEATER YELOW L 1 3 30 VDC SSR WATER 3 4 1 2 AC IN AC OUT 8 A19 1 2 39 1 PUMP 5 OUTPUT10 H01SU02NSTS 1 Electric control for horizontal autoclave with one sliding door...

Page 109: ...Page 104 of 117 pages XPCS Manual...

Page 110: ...target platform Calibration adjusting analog input presentation value by changing gain and offset values Overview XPCS is a Data exchange program that lets you perform downloading of PCS code download...

Page 111: ...t box type serial port number connected to the PCS Target platform or modem port number to remotely connection In Baudrate text box type the PCS Target platform baud rate Usually the value is 19200 Wa...

Page 112: ...wnloading and restored after downloading is completed If Get and Set Parameters checked when program performing download all parameters will be stored before PCS code downloading and restored after do...

Page 113: ...if COM Port is available Detect modem Dial a phone number Wait for connection establishment Check if remote target platforms are connected If one of the tasks fails the program will abort connection...

Page 114: ...tion window The calibration window will try to connect with the PCS Target platform The connection tasks are Check if target is connected In the status bar Looking for machine is displayed Upload all...

Page 115: ...on tool With this tool you can calibrate the selected analog input Description of the Calibration tool Gain text box use it for manual inserting of the Gain value Offset text box use it for manual ins...

Page 116: ...and offset calculation see User Manual supplied with PCS Target platform Pressing Calculate button will calculate new Gain and Offset values The new values will be displayed in the Gain and Offset te...

Page 117: ...program e g 1 instruments The message Uploading Parameters will be displayed in the status bar Download file The program will display Downloading dialog window with progress bar and counter of the dow...

Page 118: ...s and Gain Offset tasks are displayed only if the relevant options were selected in the Options window Expectable errors list Can not upload Gain and Offset Description This message may be displayed d...

Page 119: ...download another file Fail download Parameters Description This message may be displayed during download process when the program is trying to download Parameters Reason Probably a communication failu...

Page 120: ...text boxes Tips Type the right Numeric data in the text box The Actual High value is not in range The Actual Low value is not in range The Read High value is not in range The Read Low value is not in...

Page 121: ...et value displayed in Gain or Offset text boxes are not numeric data Tips Type numeric value in Gain or Offset text boxes Illegal Port number Description This message is displayed when the user is pre...

Page 122: ...answer command determination Main Startup First Row 2 Connect RS232 to Modem Converter according the following diagram 3 Check the Jumpers State according RS232 communication 4 Turn On the Modem 5 Tu...

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