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Technician Manual 3840
Technician Manual 3840
MANUAL
1. INTRODUCTION 4
2. SYMBOL DESCRIPTION 4
3. INSTALLATION INSTRUCTIONS 5
3.1 Installation Site ............................................................................................ 5
3.2 Connection of the pressure regulator........................................................... 5
4. TESTS 9
4.1 Installation Tests.......................................................................................... 9
4.2 Periodical Tests ............................................................................................ 9
5. WATER QUALITY 10
5.1 Water for the Vacuum pump and drain cooling......................................... 10
5.2 Reverse Osmosis......................................................................................... 11
6. DESCRIPTION OF THE CONTROL SYSTEM. 12
6.1 Application system architecture ................................................................. 12
6.2 Description of the programmable component:........................................... 13
6.3 Software development plan: ....................................................................... 15
7. CHECKING AND CHANGING PARAMETERS AND OTHER DATA 19
7.1 Directories and subdirectories.................................................................... 19
7.2 Entering the main menu ............................................................................ 21
7.3 Cycle Parameters (Custom 1)..................................................................... 22
7.4 Inputs/Outputs ........................................................................................... 29
7.5 Calibration ................................................................................................ 31
Current value31
7.6 History........................................................................................................ 33
7.7 Maintenance .............................................................................................. 35
7.8 Advanced Options ...................................................................................... 40
7.9 Version information................................................................................... 44
8. REPLACING ELEMENTS 47
8.1 Replacing the Circuit Breaker.................................................................... 47
8.2 Replacing the Safety Valve......................................................................... 48
8.3 Replacing the Door Gasket ........................................................................ 49
8.4 Replacing the door cover............................................................................ 50
8.5 Replacing the steam generator................................................................... 54
8.6 Replacing Heating elements....................................................................... 56
8.7 Cleaning and Replacing the Water Level Electrodes ................................. 56
1.1. Generator Side Gauge Glass Indicator Tube ............................................ 57
1.2. Draining the generator............................................................................... 58
8.8 Replacing the Printer ................................................................................. 59
8.9 Replacing the Door Switch......................................................................... 61
8.10 Replacing the air filter ............................................................................... 62
8.11 Replacing the locking motor ...................................................................... 63
Page 1 of 102 Pages
FRONT VIEW..................................................................................................................... 7
WATER OUTLET STRAINER ......................................................................................... 84
PIPING DRAWING – MODEL 3840/3850/70 ELVPVG .................................................. 91
ELECTRICAL WIRING DIAGRAM FOR AUTOCLAVE WITH 380V – PAGE 1 OF 8. 92
ELECTRICAL WIRING DIAGRAM FOR AUTOCLAVE WITH 380V – PAGE 2 of 8... 93
ELECTRICAL WIRING DIAGRAM FOR AUTOCLAVE WITH 380V – PAGE 3 of 8... 94
ELECTRICAL WIRING DIAGRAM FOR AUTOCLAVE WITH 380V – PAGE 4 of 8... 95
ELECTRICAL WIRING DIAGRAM FOR AUTOCLAVE WITH 380V – PAGE 5 of 8... 96
ELECTRICAL WIRING DIAGRAM FOR AUTOCLAVE WITH 380V – PAGE 6 of 8... 97
ELECTRICAL WIRING DIAGRAM FOR AUTOCLAVE WITH 380V – PAGE 7 of 8... 98
ELECTRICAL WIRING DIAGRAM FOR AUTOCLAVE WITH 380V – PAGE 8 of 8... 99
ELECTRICAL WIRING DIAGRAM FOR THE GENERATOR .................................... 100
SWITCH BOX WIRING DIAGRAM .............................................................................. 100
OPEN SWITCH BOX...................................................................................................... 101
CLOSED SWITCH BOX................................................................................................. 102
2. SYMBOL DESCRIPTION
Stand by
1 2 3 4 5 6
FLOW DIRECTION
6 10
5
7
8
11
4
9
12
13
2
14
1 15
No. Description
1 Front leg
2 Rear leg
3 Left service door
4 Left service door grip
5 Left service door lock
6 Door cover
7 Pressure gauge
8 Display
9 Keyboard
10 Printer cover
11 Paper slot and paper cutter
12 USB socket
13 RJ45 connector
14 Main switch
15 Printer
15
1 14
13
2
12
3
4 5 6 7 8 9 10 11
5. WATER QUALITY
Physical Characteristics and Maximum acceptable
contaminant levels in water or steam, for steam generator and
sterilizers
(According to EN 285:2006).
Contaminants Contaminants
in water in condensate
supplied at steam inlet
to generator to sterilizer
Evaporate residue ≤ 10 mg/l N/A
Silicate (SiO2 ≤ 1 mg/l ≤ 0.1 mg/l
Iron ≤ 0.2mg/l ≤ 0.1mg/l
Cadmium ≤ 0.005 mg/l ≤ 0.005 mg/l
Lead ≤ 0.05 mg/l ≤ 0.05 mg/l
Rest of heavy metals except iron,
≤ 0.1 mg/l ≤ 0.1 mg/l
cadmium, lead
Chloride (Cl) ≤ 2 mg/l ≤ 0.1 mg/l
Phosphate (P2O5) ≤ 0.5 mg/l ≤ 0.1 mg/l
Conductivity (at 25°C) ≤ 5 µs/cm ≤ 3 µs/cm
pH value (degree of acidity) 5 to 7.5 5 to 7
Hardness (Σ ions of alkaline earth) ≤ 0.02 mmol/l ≤ 0.02 mmol/l
Appearance Colourless, clean, without sediments
Main board
Analog
Description JP
inputs
PT100-1 PT-100 Chamber Temperature J2
PT100-2 PT-100 Ref Temperature1 J3
PT100-4 PT-100 Drain (option) J5
Pressure 1 4-20mA main chamber pressure control J7/1
Electrode 1 Water level camber/generator control 1 J11/1
+ -
J5
BT1
P4
J8
T1
J3
P2
J4
P3
J3 J6
J1 J4
J12
Digital outputs
Example
The main board sends:
01;00;0003;0004;
01 Ask to Read inputs.
00 not transfer information.
0003 Request number 3
0004 Checksum to verify the request
SECOND
DIRECTORY SUBDIRECTORY
SUBDIRECTORY
Cycle Parameters –
See sec. 6.4 “Cycle Parameters
applicable only for Custom
(Custom 1)”
1 and Custom 2 programs
Print Rate All
System Parameters Print Rate Sterilization
Screen Saver
View digital inputs state
View digital outputs state
Inputs / Outputs
Test digital outputs
View analog inputs state
Last 10 cycles
View old cycle history Last 50 cycles
History
All cycles history
Export history to USB
set date and time
Export gain offset to USB
Reset atmospheric pressure
Maintenance
Test RTC
Printer test
Print all gain and offset
Start cycle by clock
Enable cycles
Set language
Set Temperature units
Advanced options Set pressure units
Export all settings to USB device
Add Custom Program
Set Master IP address
Set mac address
View current version information
View factory default version
Version information
information
View previous version information
Main board
In order to exit the ENTER CODE screen move the cursor to Exit by
pressing START/STOP Key. when Exit is blinking press UP or
DOWN keys.
Subdirectory Property
Pulse A Count
Pulse A Stay Time
Pulse A Low Pressure
Pulse A High Pressure
Create Pulse
Pulse B Count
Pulse B Stay Time
Pulse B Low Pressure
Pulse B High Pressure
Sterilization Temperature
Sterilization Sterilization Time
F0 Mode
Cool mode
Cooling Cool End Temperature
Cool Exhaust Rate
Exhaust Exhaust Mode
Dry Dry Heat On 1
7.3.2 Heat
7.3.2.1 Sterilization Temperature
7.3.3 Sterilization
7.3.3.1 Sterilization Temperature
See 7.4.2.1 Sterilization Temperature
7.3.3.3 F0 Mode
Repeat the action mention in 7.4.2.1 Sterilization
Temperature
7.3.5 Exhaust
Exhaust Mode
7.4 Inputs/Outputs
7.5 Calibration
7.5.1 Calibration components
This directory describes the calibration of 4 sensors in the
Sensor name Sensor function
1. ChambPress Reads the pressure in the chamber.
2. ChambTemp Reads the temperature in the chamber.
7.6 History
When entering the SET DATE AND TIME screen, the time and
date are displayed. The cursor is blinking on the "second" digit.
The time is displayed in the upper row in the form "HH:MM:SS".
The hour range is 24 hour (i.e. from "0" to "24")
The date is displayed in the lower row in the form
"DD:MMM:YYYY".
When entering the Test RTC screen, the time is displayed. The
cursor is blinking on the right "minute" digit.
The time is displayed in the form "mm".
1. To increase or decrease the time use the UP or DOWN keys.
2. To move the cursor from one digit to another press the
START/STOP key.
3. After choosing the required time move the cursor by pressing
START/STOP key to start and press UP or DOWN keys
4. The test will start, the following screen is an example to
completed test for 1 minute
This subdirectory enables the operator to print all the gain and
offset values.
When pressing START/STOP key on the Print all gain and offset
item the printer will print out the following:
Drain Temperature
G:000.0400;O:-004.0000
Chamber Temperature
G:000.0400;O:-004.0000
Ref Temperature 1
G:000.0400;O:-004.0000
Chamber Pressure
G:000.1250;O:-100.0000
The circuit breaker is located on the rear of the autoclave (See Rear View).
1. Disconnect the wires (1, 2) from the circuit breaker.
1 2
2. Remove four screws connecting the circuit breaker to the panel (3).
3
4
2
5
5 Rear wall
Rear wall
6 7 7 8 6 7 7 8
ASME CE
1 8
7
2
6
3
5 2
2
1
1 2
4. Lift the door and release the edge of the spring holder (16)
from the slot (15).
15
16
11
1. Assemble door bracket (5) to the door cover (4) with 10 screws
(6).
4
2. Assemble the axis bridge (10) to the axis seat (7) with a pin (9)
and cotter pin (8).
10
11
12
4. 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.
13
14
5. Lift the door and insert the edge of the spring holder (16) into
the slot (15).
16
6. 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).
Make sure that the electric cord is disconnected from the power source and
that there is no pressure in the autoclave chamber and generator.
Open the generator drain valve and let the water flow.
Drain the generator (see …).
Close the water tap and disconnect the water inlet pipes.
1. Unscrew the screws (1) fastening the generator compartment cover and
remove it.
2. Disconnect the wires (2) from the water level electrodes.
3. Disconnect the neutral heating element electric wires (3) from the
porcelain terminal.
4. Disconnect the piping as follows:
a. Disconnect the water inlet pipe (5)
b. Disconnect the steam-to-chamber Teflon tube (6).
c. Disconnect the drain tube.
d. Verify that all the pipes are disconnected (?)
5. Unplug the solenoid (7) from the solenoid valve (8) mounted on the top
of the generator.
6. Pull out the thermostat (4).
7. Unscrew and remove the screws (9) connecting the generator bracket to
the autoclave base frame.
8. Disconnect the Generator Side Gauge Glass Indicator Tube (see replacing
the Generator Side Gauge Glass Indicator Tube).
9. Remove the generator from the autoclave.
10. Replace the generator with a new one.
8 7
10 3 4 2 6 9
Make sure that the electric cord is disconnected from the power source and
that there is no pressure in the autoclave chamber and generator.
Open the generator drain valve and let the water flow.
Drain the generator (see …).
Close the water tap and disconnect the water inlet pipes.
1. Perform steps 1-6 of the procedure 8.5 Replacing the steam generator.
2. Unscrew the hexagon nut (10, above) from the heating elements base.
3. Replace the heating elements.
4. Reconnect all the elements and close the service door.
The three electrodes of the water level control system are located on top of the
steam generator.
8.16.1 Cleaning
1. Take the generator out of the autoclave (see para. 8.13
"Replacing the generator").
2. Unscrew the big nuts (1).
3. Note which wire belongs to which electrode and remove the
three electrodes.
4. Clean the electrodes.
5. Reassemble the three electrodes into their places.
6. Tighten the nuts to avoid leakage.
7. Verify that the electrodes height did not change. If there was any
change in the electrodes height, loosen the small nut (3), adjust
the height and tighten the nut.
8. Return the generator to the autoclave and reconnect the piping
and wiring as required (see para. 8.13 "Replacing the
generator").
9. Test the unit.
8.16.2 Replacing
1. Take the generator out of the autoclave (see para. 8.13
"Replacing the generator").
2. Unscrew the big nuts (1).
3. Note which wire belongs to which electrode and remove the
three electrodes.
1. 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.
2. Drain the water.
3. Remove the protective rod (4) that protects the glass tube (5).
4. Loosen the two nuts (3) on both sides of the glass tube. Slip the upper
one down, and then remove the tube
5. Replace the tube with a new one.
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.
2 1
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 the outer cover.
2. Turn the panel to reveal the internal part and the electrical connectors.
3. Unplug the board connectors (3) and the printer connectors (2). Verify
that you know where plug each is connected.
4. 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. Repeat this with the second fastener.
5. Pull the printer out of its seat (the hole in the panel).
6. Replace the printer with a new printer.
7. Inset the fasteners. Verify that they are inserted firmly.
8. Connect the printer's connectors
9. Connect all the connectors of the board.
10. Lay the control panel on its place.
11. Fasten the panel with the screws (1).
1 2 3 4 5
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 the outer cover.
Note:
The locking motor can be replaced with an open door or with a closed
door.
4
8
5
7 6
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.
Allow the autoclave to cool before removing the outer cover.
1. Open the relevant service door to reveal the faulty BACCARA solenoid
valve.
2. Unscrew and remove nut (1).
3. Remove the coil (2).
4. 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.
5. Reassemble the coil (2) and the nut (1).
6. Re-install the autoclave cover.
5 4 3 2 1
Caution!
Before starting, ensure that there is no pressure in the chamber, coil or
generator.
Allow the autoclave to cool before removing the outer cover.
Caution!
Before starting, ensure that there is no pressure in the chamber, coil or
generator.
Allow the autoclave to cool before removing the outer cover.
8.15 Replacing the power supplies, water level board and relays
Caution!
Before starting, disconnect the autoclave from the power source.
For description of items – see table below.
6 7
DESCRIPTION OF ITEMS
The pressure switches are factory regulated, however in order to adjust the
steam pressure, follow this procedure:
Operating control pressure switch
To set the pressure in which the heating elements turn off turn the bronze
color pressure switch knob. Turn it clockwise to decrease pressure and
counterclockwise to increase the pressure.
To set the pressure in which the generator restarts (i.e. the pressure
differential between the turn-off and the turn-on pressures) turn the black
color pressure switch knob. Turn it clockwise to decrease pressure and
counterclockwise to increase the pressure.
The pressure switch will be set to an output steam pressure, 3.5 - 4 Bars.
Limit control pressure switch
To set the cut-off pressure, turn the bronze color pressure switch knob.
Turn it clockwise to decrease pressure and counterclockwise to increase
the pressure.
The pressure switch will be set to a cut-off pressure of 5 Bars.
Differential Reset
pressure lever
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.
Message /
Symbol / Failure Description Corrective Action
Problem
1 The main switch is in ‘OFF’ 1 Turn the main switch to
position. the ‘On’ position.
(see front view drawing).
2 The power cord is disconnected 2 Make sure the power cord
The machine is
from the machine or the mains. is connected properly to
not responding
the machine and the mains.
(see rear view drawing)
3 The circuit breaker has tripped. 3 Lift the circuit breaker
lever.
1 The Paper roll is not installed in 1 Install the paper roll in the
The printer
the right way. right way. Only one side of
prints, but
(see Printer Handling in the paper is printable.
nothing is
Operator's manual) (see Printer Handling in
printed on the
Operator's manual)
paper.
2 Faulty printer. 2 Replace the printer.
1 No paper is inserted in the printer. 1 Make sure the paper roll
(see Printer Handling in is inserted in the printer.
Operator's manual) (see Printer Handling in
operator's manual)
2 No obvious reason. 2 Switch off the machine and
switch it back on for restart
The printer
3 If printer's LED is on – faulty 3 Replace the printer.
does not print.
printer.
4 Check 24V input to the printer. If
none:
Discontinuity between power Fix discontinuity.
supply and printer.
Faulty power supply. Replace power supply.
1 The door gasket is dirty. 1 Clean the door gasket.
The machine is
(see Daily Maintenance in (see Daily Maintenance in
leaking at the
Operator's manual) Operator's manual).
door
2 The door gasket is damaged. 2 Replace the door gasket.
1 This message is displayed if the 1 Perform a new cycle.
temperature drops for more than 1
second below the sterilization
Low Temp
temperature during sterilization
cycle.
2 Door gasket is leaking. 2 Replace the door gasket.
High Temp 1 This message is displayed if the 1 Perform a new cycle.
N Circuit breaker Y
on ON position
Turn C.B. on
N Problem Y
persists
Problem solved
Faulty C.B.
Replace C.B.
N 230V at input of Y
small power supply
N Y
24VDC at output
of power supply
N Y
24VDC at input of
control unit
N Valve Y
opens
Disconnect
valve's plug
Valve O.K.
N Voltage in plug Y
when control unit
sends a signal
Faulty coil
Wire
discontinuity
Replace coil
Fix
discontinuity
5. The safety valve 5.1 The steam pressure is higher than 5.1 Check cause and remedy it,
blows. the working pressure. See section 4 above)
5.2 Check and replace the
5.2 The safety valve is defective. safety valve.
81. Inlet
82. Main inlet
8. GAS
83. Inlet through humidifier
RL2
RL1
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.
FROM FROM
AUTOCLAVE NETWORK GND N
GND R
N S
L T