Engineering and Maintenance Manual

ENGINEERING AND MAINTENANCE MANUAL
SD 660
HIGH TEMPERATURE STEAM STERILIZER

 SERVICE AND MAINTENANCE MANUAL
 PARTS LIST
 PIPING DIAGRAM
 WIRING DIAGRAMS
 FLOWCHARTS
 CONTROLLER MANUAL
 ENGINEERING SOFTWARE MANUAL

SERVICE AND MAINTENANCE MANUAL
SD 660
This manual includes autoclaves fitted with integral steam generators.

For units supplied with steam from an external source,
ignore any references to the boiler.
1
TABLE OF CONTENTS PAGE
1. Preventative Maintenance Servicing ................................................ 3

1.1 User maintenance ................................................................................. 3
1.2 Technical maintenance ......................................................................... 4
2. Troubleshooting.................................................................................. 6
2.1 Error messages..................................................................................... 6
2.2 Failures during a sterilizing cycle ........................................................ 10
2.3 Boiler failures ...................................................................................... 13
2
1. Preventative maintenance servicing
The autoclave is to be maintained in good working order by regular servicing of the

unit by both the user as well as technical maintenance staff.
1.1 User maintenance
Only qualified personnel should work with the autoclave after receiving suitable
training. The operator will proceed according to the operating instructions and will not
make any change in the working procedures or the process data, without the express
instructions of the person in charge.
The personnel operating the sterilizer will use protective garments and materials
according to working procedures of the establishment.
 Check that the strainer over the chamber exhaust is clear.

Before each cycle  Check that the door gaskets are clean and fully pulled back
in their grooves. If not, use a blunt instrument to push the
gaskets back into their grooves.
 Check that the items are secure on internal trolley or
shelves and are not touching the sides on the chamber.
 Check that the correct cycle has been selected for the load.
 Check that there is sufficient printer paper for the day.

Daily  Clean the face of the door gaskets with a soft cloth.
 Run a Bowie and Dick Test cycle.
 Keep the doors closed between sterilizing cycles.
 While the chamber is cold, the autoclave is switched off,

Weekly and the doors are open:
o clean the cabinet, front panels, chamber, shelves, and
trolleys using a soft damp cloth and warm household
detergent. Rinse with distilled or demineralised water.
 While the chamber is hot:

o switch off the autoclave and wait for the boiler
pressure to drop to below 20 kPa.
o open the boiler manual blowdown valve and empty
the boiler. Regulate the amount the blowdown valve is
open so that steam does not condense on the
autoclave controls.
o When the boiler is empty, close the blowdown valve.
 Check the autoclave for any leaks and tighten fittings

where necessary.
 Run a vacuum leak test.
3
1.2 Technical maintenance
The maintenance and service works will be executed only by authorized technicians,
provided with the documentation and the instruments suitable for the kind of work to
be done.
After executing the maintenance and /or repair works, the autoclave will be
thoroughly checked and tested in operation, to make sure it is in perfect operating
condition.
 Check all electrical connections for tightness, especially the

6-monthly minor service high current components such as the mains isolator, circuit
breakers and contactors.
 Remove the boiler element cover and check the electrical
connections of the elements for tightness.
 Check the element gaskets and main boiler gasket for
leaks. Tighten or replace gaskets where necessary.
 Drain the boiler.
 Remove the boiler level sensor probes from the top of the
boiler and check for scale build-up. Clean the probes and
replace. Take care not to over-tighten the probe fittings to
prevent the ferrule from cutting into the Teflon insulation.
 Open all strainers and steam traps and clean out any dirt or
debris.
 Check the water tank for any dirt at the bottom of the tank,
and clean if necessary.
 Remove the door gaskets, clean the gasket grooves, and fit
new gaskets.
 Replace the air filter with a new filter.
 Check all bolts holding the door clamps to the pressure
vessel headring.
 Check all bolts holding the door, bottom door clamp, chains
and counterweights.
 Remove the jacket, chamber and tank temperature
sensors, clean and replace.
 Clean the electrical control box using a soft brush and
vacuum cleaner to remove any dust build up.
 Check the printer paper and ribbon - replace if necessary
Once the servicing is complete, switch on the autoclave:

 test the boiler water level control system for correct
operation.
 check the current draw on each boiler element
 check the safety valves for correct operation
 check the jacket overpressure switch for correct operation
 run a vacuum leak test
 run a Bowie & Dick test
 run the sterilizing cycles and check for correct operation
4
 Carry out all work as per the 6-monthly service in
Annual major service addition to the following:
 remove the boiler elements and check for scale build up.
 megatest the resistance of each element leg and replace
the elements with new elements if necessary.
 remove the boiler end plate and check the internals of the
boiler for sediment and scale build up.
 clean the internals of the boiler
 fit a new boiler flange gasket and refit the flange
 fit new boiler element gaskets and refit the elements
 replace all non-return valves
 open all solenoid valves and check the seats and bodies
for wear or damage.
 fit all solenoid valves with new service kits
 check that the ejector is clear of any dirt
 calibrate all temperature and pressure sensors
Once the servicing is complete, switch on the autoclave:

 test the boiler water level control system for correct
operation.
 check the current draw on each boiler element
 check the correct operating pressure of the boiler
 check the safety valves for correct operation
 check the jacket overpressure switch for correct operation
 run a vacuum leak test
 run a Bowie & Dick test
 run the sterilizing cycles and check for correct operation
Statutory inspections Periodic safety inspections or tests such as electrical

or pressure vessel testing must be carried out in
accordance with any local laws or regulations.
5
2. Troubleshooting
2.1 Error messages.
The controller monitors the status of the temperatures, pressures, and various
switches and sensors. Should the controller detect a failure an error message will
appear on the display. If an operator tries to start a cycle while an error is present,
the printer will print the error and the cycle will not start. If the error occurs during a
cycle the error will also be printed on the cycle printout.
ERROR MESSAGE CAUSE OF ERROR

Vacuum pump water low The water tank level is below the bottom level
switch. Possible failure of the water supply.
Jacket temperature high Jacket temperature is 5 C greater than the
sterilizing temperature for the selected cycle.
This can occur when selecting a cycle with a
lower sterilizing temperature than the current
selected cycle and the jacket has not yet had
time to cool to the new sterilizing temperature
of the selected cycle.
Jacket temperature sensor is faulty.
Steam to jacket valve is not shutting off

properly when de-energised
Steam to jacket valve is not being de-

energised due to a faulty solid state relay.
Jacket temperature low Jacket temperature is 5 C less than the
sterilizing temperature for the selected cycle.
This can occur when selecting a cycle with a
higher sterilizing temperature than the current
selected cycle and the jacket has not yet had
time to heat to the new sterilizing
temperature of the selected cycle. This will
also occur when the autoclave is heating up
from cold after being switched off.
Boiler or mains steam pressure is low.
Jacket temperature sensor is faulty or the

jacket steam traps are not removing
condensate form the jacket drain.
Steam to jacket valve is not opening when

energised.
Steam to jacket valve is not being energised

due to a faulty solid state relay.
6
Tank temperature high Water tank temperature is > 80 C.
Water tank temperature sensor is faulty.
Failure of the water supply.
Water valve does not open when energised.
Water valve is not energised due to faulty

relay.
Water valve relay is not energised due to

faulty controller output module.
Tank temperature low Water tank temperature is < 5 C.
Water tank temperature sensor is faulty.
Water supply temperature is too low.
Power failure This error will be visible on the display if a

UPS system is installed to keep the controller
powered up while a power failure is
occurring.
The error will be printed when the power is
restored and the autoclave was in a cycle
when the power fail occurred.
Power supply failure to the autoclave.
Control circuit breaker has tripped.
Emergency stop button has been pressed.

Module not found Faulty controller module
Poor connection between module and
motherboard.
Chamber over-temperature Chamber temperature exceeds the maximum
permissible temperature for the chamber.
This causes the steam to chamber valve to
be shut off.
Chamber over-pressure Chamber pressure exceeds the maximum
permissible working pressure for the
chamber. This causes the steam to chamber
valve to be shut off.
Chamber temperature low Chamber temperature drops below sterilizing
temperature during a cycle.
Chamber temperature probe fault
Bleed orifice blocked
Chamber strainer blocked
7
Chamber drain blocked
Boiler or mains steam pressure low
Bleed valve does not open when energised
Bleed valve not being energised due to faulty

relay.
Chamber overloaded
Chamber temperature high Chamber temperature > 5 C above sterilizing
temperature during a cycle.
Chamber pressure probe fault
Boiler or mains steam pressure too high

Jacket overpressure This alarm is activated by the jacket pressure
switch.
Jacket temperature sensor faulty
Jacket steam traps are not removing

condensate form the jacket drain.
Steam to jacket valve is not shutting off

properly when de-energised
Steam to jacket valve is not being de-

energised due to a faulty solid state relay.
Jacket temperature error Jacket temperature is out of range
Faulty jacket temperature sensor
Faulty analogue input module.

Tank temperature error Water tank temperature is out of range
Faulty water tank temperature sensor

Control temperature error Control temperature is out of range
Faulty chamber temperature sensor
8
Monitor temperature error Monitor (printer) temperature is out of range
Faulty chamber temperature sensor

Chamber pressure error Chamber pressure is out of range
Faulty chamber pressure sensor
Faulty pressure input module.

Dirty door fault or jammed Automatic door fails to fully open or fully
close within a set period of 20 seconds.
Dirty door jammed by gasket or other object.
Dirty door motor faulty
Dirty door motor contactor faulty
Dirty door controller output relay faulty.
Dirty door switches faulty
Door overload tripped

Clean door fault or jammed Automatic door fails to fully open or fully
close within a set period of 20 seconds.
Clean door jammed by gasket or other

object.
Clean door motor faulty
Clean door motor contactor faulty
Clean door controller output relay faulty.
Clean door switches faulty
Door overload tripped
9
2.2 Failures during a sterilizing cycle
Every cycle comprises a number of stages, each of which has a target value of time,
pressure, or temperature. If the target value (temperature or pressure) is not reached
within a set time, the cycle will abort to a selected stage in order to end the process
as quickly and safely as possible.
The same abort procedure is used when there has been a power failure. When the
power is restored, the cycle will immediately go to the abort stage.
A typical Packs @ 134C cycle is shown below.
Example 1. If the autoclave is in the exhaust stage (004) and does not drop down
to a pressure of 120 kPa within a set period, the cycle will abort to stage 17.
Example 2. If the autoclave is in the steam injection stage (014) and does not
reach a temperature of 134 C within a set period, the cycle will abort to stage 17.
The abort timeout periods are set as follows:
Draw vacuum 30 min

Steam pulse 10 min
Steam inject 20 min
Air admission 10 min
Slow exhaust 120 min
10
Possible causes of failures during a sterilizing cycle are as follows:
FAILURE POSSIBLE CAUSES

Failure to draw vacuum Chamber drain blocked
Chamber exhaust strainer blocked
Exhaust valve not opening
Vacuum pump not running
Water supply to vacuum pump blocked
Air leak into the system
Water supply failure
Water temperature too hot
Chamber pressure sensor faulty
Autoclave too heavily loaded
Insufficient steam for an effective steam flush

Failure to reach steam pulse pressure Low boiler or mains steam pressure
Steam to chamber valve does not open
Steam to jacket valve does not open
Exhaust valve does not close

Failure to reach steam injection temperature Steam to chamber valve does not open
Bleed valve does not open
11
Failure to reach air admission pressure Air valve not opening
Air filter blocked
Exhaust valve not closing
Bleed valve not closing

Failure to reach slow exhaust pressure Chamber drain blocked
Chamber exhaust strainer blocked
Bleed valve not opening
Vacuum pump not running
Water supply to vacuum pump blocked
Water supply failure
Steam to chamber not sealing properly

Failure to reach or maintain sterilizing Steam to chamber valve does not open
temperature.
Bleed valve does not open
12
2.3 Boiler failure
The boiler generates steam at approximately 350 - 400 kPa. This will temporarily
drop during a sterilizing cycle due to the high demand for steam during the
preconditioning stages of the cycle, but should recover sufficiently to enable the cycle
to proceed and complete successfully.
Possible failures that can occur are as follows:
Low boiler pressure Element circuit breaker tripped

Element contactor failed open
Boiler pressure switch faulty
Failed water supply to boiler:
Failed water supply to water tank
Failed boiler feed pump
Feed pump contactor tripped
Motor circuit breaker tripped
Feed pump not primed
Blockage in feed line
Faulty level probes
Faulty level switch
Jacket steam traps not closing
One or more elements failed
High boiler pressure (safety valve blows) Boiler pressure switch faulty
Element contactor failed closed
Faulty safety valve
www.steridium.com sales@steridium.com
PO Box 5296, Q Super Centre, Queensland, 4218, Australia
Tel: +61 7 55 931 352 Fax: +61 7 55 931 876
13
PARTS LIST
SPARE PARTS LIST - SD 660 AUTOCLAVE - DOUBLE DOOR - SINGLE STEAM GENERATOR
ITEM DESCRIPTION RECOMMENDED QUANTITY USED ON

6 month 12 month
Emergency
Minor Major
stock
Service Service
CONSUMABLES
1 Printer roll 50 Panel printer
2 Printer ribbon 10 Panel printer
SERVICING AND EMERGENCY SPARES

3 SD660 door seal 2 2 1 door
4 Water tank float switch 1 water tank level control
5 Pt100 simplex 6mm temperature sensor (water tank temperature) 1 water tank temperature sensor
6 Pt100 simplex 3mm temperature sensor (jacket temperature) 1 jacket temperature sensor
7 Pt100 duplex 6mm temperature sensor (chamber temperature) 1 chamber temperature sensors
8 1/2" non - return valve 2 1 air inlet, boiler inlet
9 1" non - return valve 2 1 exhaust, ejector pump
10 K302-037 Valve service kit (for 1/4" 2-way solenoid valve type SCE263A300 ) 4 1 steam to gasket valves, bleed valve, blowdown valve
11 K322-042 Valve service kit (for 1/4" 3-way solenoid valve type SCHBX8320G186E) 2 1 steam to / from gasket valves
12 K304-669 Valve service kit (for 3/4" 2-way steam solenoid valve type SUD222E2 ) 1 1 steam to chamber valve
13 K304-032 Valve service kit (for 3/4" 2-way steam solenoid valve type SUD222A49 ) 1 1 steam to jacket valve
14 K304-392 Valve service kit (for 1" 2-way steam solenoid valve type SUD22025 ) 1 1 exhaust valve
15 K302-272 Valve service kit (for 1/2" 2-way air solenoid valve type SCD210C94) 1 1 air valve
16 K302-273 Valve service kit (for 1/2" 2-way water solenoid valve type SCD210D2) 1 1 water valve
17 TH13A steam trap kit 1 jacket drain
18 Air filter 1 1 1 air inlet filter
19 Boiler element 12 kW on 2" boss 3 boiler
20 Boiler element gasket 3 3 boiler element seal
21 Boiler flange gasket 1 1 boiler flange seal
22 Water level probe 1 Boiler water level control
23 24VDC relay 1 Controller output signal interface
24 Solid state relay 1 Chamber valve control, jacket valve control
25 Power fail relay 1 Power fail input signal
SPARE PARTS LIST - SD 660 AUTOCLAVE - DOUBLE DOOR - DOUBLE STEAM GENERATOR
ITEM DESCRIPTION RECOMMENDED QUANTITY USED ON

6 month 12 month
Emergency
Minor Major
stock
Service Service
CONSUMABLES
1 Printer roll 50 Panel printer
2 Printer ribbon 10 Panel printer
SERVICING AND EMERGENCY SPARES

3 SD660 door seal 2 2 1 door
4 Water tank float switch 1 water tank level control
5 Pt100 simplex 6mm temperature sensor (water tank temperature) 1 water tank temperature sensor
6 Pt100 simplex 3mm temperature sensor (jacket temperature) 1 jacket temperature sensor
7 Pt100 duplex 6mm temperature sensor (chamber temperature) 1 chamber temperature sensors
8 1/2" non - return valve 3 1 air inlet, boiler inlet
9 1" non - return valve 2 1 exhaust, ejector pump
10 K302-037 Valve service kit (for 1/4" 2-way solenoid valve type SCE263A300 ) 5 1 steam to gasket valves, bleed valve, blowdown valve
11 K322-042 Valve service kit (for 1/4" 3-way solenoid valve type SCHBX8320G186E) 2 1 steam to / from gasket valves
12 K304-669 Valve service kit (for 3/4" 2-way steam solenoid valve type SUD222E2 ) 1 1 steam to chamber valve
13 K304-032 Valve service kit (for 3/4" 2-way steam solenoid valve type SUD222A49 ) 2 1 steam to jacket valve
14 K304-392 Valve service kit (for 1" 2-way steam solenoid valve type SUD22025 ) 1 1 exhaust valve
15 K302-272 Valve service kit (for 1/2" 2-way air solenoid valve type SCD210C94) 1 1 air valve
16 K302-273 Valve service kit (for 1/2" 2-way water solenoid valve type SCD210D2) 1 1 water valve
17 TH13A steam trap kit 1 jacket drain
18 Air filter 1 1 1 air inlet filter
19 Boiler element 12 kW on 2" boss 3 boiler
20 Boiler element gasket 6 3 boiler element seal
21 Boiler flange gasket 2 1 boiler flange seal
22 Water level probe 1 Boiler water level control
23 24VDC relay 1 Controller output signal interface
24 Solid state relay 1 Chamber valve control, jacket valve control
25 Power fail relay 1 Power fail input signal
PIPING DIAGRAM
SD660
This piping diagram is for a double door sterilizer

with a single steam generator.
For units with single doors,

ignore the second set of gasket valves.
For units with double steam generators,

all relevant components will be duplicated except the feed pump.
For units with external steam supplies,

ignore the steam generator and feed pump circuits.
WIRING DIAGRAMS
LINE 1 MCB1
381
LINE 2
382
LINE 3
383
NEUTRAL
00
EARTH CTR
1 ELEMENTS
2 ELEMENTS
3 ELEMENTS
AUX 220 VAC

00
BOILER
F.S.1 N/O ELEMENTS
P.S COIL 00
6 4 3 1 2
F.S.1
6 6 5 00
COIL
PUMP CTR COIL

95 96 8 00
OIL
F.S.2 N/C BOILER WATER VALVE

6 4 2 7 00
F.S.2
6 6 5
COIL
P.S - PRESSURE SWITCH
F.S - FLOATLESS SWITCH

CONTROLLER FLOWCHARTS
STEAM / LTSF STERILIZER
EMBEDDED CONTROL SYSTEM
LEGEND
The following symbols are used throughout the flowcharts and diagrams:
Process or Menu
Decision / Check for a condition
Large display
LED display on controller
Printout
CONTENTS
• Basic operation
• Cycle selection
• Main menu
• Edit variables
• Edit advanced variables
• Cycle parameters
• Print reports
• Set date
• Set time
• Analogue calibration
• Edit passwords
• Monitor digital inputs
• Monitor digital outputs
• Monitor analogue inputs
• Manual control
MIEDS AC204 DOC02 Page 1 of 16

BASIC OPERATION FLOWCHART
START-UP
Initialize system and all modules

and waits for analogue inputs to
stabilize.
Was the cycle interrupted by a power failure?
Yes No
Is the door closed?
Yes No
Steam cycle: Continue from abort stage SYSTEM IDLE

LTSF cycle: Continue from last position
Start Cycle button pressed?
Yes No
RUN CYCLE System good (no alarms or faulst)? Print

faults
Yes No
Door(s) closed?
Yes No
End of cycle
Sound alarm 5 seconds every minute
and wait for door to open
Unsterile Sterile
Continuously sound alarm

and wait for door to open

CYCLE SELECTION AND DISPLAY
SYSTEM
IDLE IDLE
Manual Control?
Off On
Show cycle name Flash cycle name and TOP LINE

“manual control”
Cycle Select button pressed?
Yes No
Select next cycle
Faults or alarms?
Yes No
FLASH ERRORS Show door status BOTTOM LINE

MAIN MENU
Hold down SET for 5 seconds

SYSTEM MAIN MENU
IDLE
ESC button
IDLE or no button activity for 20 seconds
(See page 5) EDIT VARIABLES VAR
UP DOWN
(See page 6) ADVANCED VARIABLES A-VAR
UP DOWN
(See page 7) CYCLE PARAMETERS CYCLE
(See page 8) PRINT REPORTS PRINT
(See page 9) SET DATE 01/01/2004 DATE
(See page 10) SET TIME 10:00:00 TIME
(See page 11) ANALOGUE CALIBRATION CAL
(See page 12) EDIT PASSWORDS PASS
(See page 13) DIGITAL INPUTS DIN
(See page 14) DIGITAL OUTPUTS DOUT
(See page 15) ANALOGUE INPUTS AIN
(See page 16) MANUAL CONTROL MAN

EDIT VARIABLES

SYSTEM MAIN MENU
IDLE
Save data if values changed EDIT VARIABLES VAR
ESC
SET
Menu enabled?
Show error
message
Yes No
Password required?
No Yes
Enter password
SET ESC
Password correct?
Show error
message
Yes No
SELECT VARIABLE TO EDIT

by pressing UP or DOWN
# Description
V#
Value
SET ESC
EDIT VALUE
# Description
Value
Step size Value
SET ESC
Revert back to old value
Accept new value

EDIT ADVANCED VARIABLES

SYSTEM MAIN MENU
IDLE
ESC
UPx1
ADVANCED VARIABLES A-VAR
SET
Menu enabled?
Show error
message
Yes No
Password required?
No Yes
Enter password
SET ESC
Password correct?
Show error
message
Yes No
SELECT VARIABLE TO EDIT

# Description
V#
Value
SET ESC
EDIT VALUE
# Description
Value
Step size Value
SET ESC
Accept new value

CYCLE PARAMETERS

SYSTEM MAIN MENU
IDLE
ESC
UPx2
CYCLE PARAMETERS CYCLE
SET
Menu enabled?
Show error
message
Yes No
Password required?
No Yes
Enter password
SET ESC
Password correct?
Show error
message
Yes No
SELECT PARAMETER TO EDIT

# Description
Value
SET ESC
EDIT VALUE
# Description
Value
Step size Value
SET ESC
Accept new value

PRINT REPORTS

SYSTEM MAIN MENU
IDLE
ESC
UPx3
or no button activity for 20 seconds
IDLE
PRINT REPORTS PRINT
SET
SELECT REPORT TO PRINT
NORMAL VARIABLES VAR ESC

UP
NORMAL VARIABLES MIN. NVMIN
NORMAL VARIABLES MAX. NVMAX
ADVANCED VARIABLES A-VAR
SET PRINT
ADV. VARIABLES MIN. AVMIN
REPORT
ADV. VARIABLES MAX. AVMAX
CALIBRATION DATA CAL
DIGITAL INPUTS DIN
DIGITAL OUTPUTS DOUT
ANALOGUE INPUTS AIN
DOWN
SELECTED CYCLE CYCLE

SET DATE

SYSTEM MAIN MENU
IDLE
ESC
UPx4
IDLE
SET DATE 01/01/2004 DATE
SET
SELECT DATE TO EDIT

ESC
UP SET YEAR YEAR
SET MONTH MONTH
SET
SET DAY DAY
DOWN
SET DAY OF WEEK WDAY
EDIT SELECTED DATE
SET ESC
Set the new date

SET TIME

SYSTEM MAIN MENU
IDLE
ESC
UPx5
IDLE
SET TIME 10:00:00 TIME
SET
SELECT TIME TO EDIT

ESC
UP
SET HOUR HOUR
SET MINUTES MIN
SET
DOWN SET SECONDS SEC
EDIT SELECTED TIME
SET ESC
Set the new time

ANALOGUE CALIBRATION

SYSTEM MAIN MENU
IDLE
ESC
UPx6
ANALOGUE CALIBRATION CAL
SET
Menu enabled?
Show error
message
Yes No
Password required?
No Yes
Enter password
SET ESC
Password correct?
Show error
message
Yes No
SELECT CALIBRATION PROCEDURE

# Analogue description
# Desc.
Calibration procedure
SET+ESC ESC
Pre-calibration procedures
Post-calibration procedures
EDIT VALUE
# Description
Value
Step size Value
SET ESC
Revert back to old values
Accept new values

EDIT PASSWORDS

SYSTEM MAIN MENU
IDLE
ESC
UPx7
EDIT PASSWORDS PASS
SET
Menu enabled?
Show error
message
Yes No
Password required?
No Yes
Enter password
SET ESC
Password correct?
Show error
message
Yes No
SELECT PASSWORD TO EDIT

EDIT PASSWORDS
Desc.
Description
SET ESC
EDIT VALUE
Description
Value
Step size Value
SET ESC
Revert back to old password
Accept new password

MONITOR DIGITAL INPUTS

SYSTEM MAIN MENU
IDLE
ESC
UPx8
IDLE
DIGITAL INPUTS DIN
SET
ESC
SELECT DIGITAL
UP INPUT TO MONITOR
DIGITAL INPUT State

DOWN # Description State

MONITOR DIGITAL OUTPUTS

SYSTEM MAIN MENU
IDLE
ESC
UPx9
IDLE
DIGITAL OUTPUTS DOUT
SET
ESC
SELECT DIGITAL
UP OUTPUT TO MONITOR
DIGITAL OUTPUT State

DOWN # Description State

MONITOR ANALOGUE INPUTS

SYSTEM MAIN MENU
IDLE
ESC
UPx10
IDLE
ANALOGUE INPUTS AIN
SET
ESC
SELECT ANALOGUE
UP INPUT TO MONITOR
ANALOGUE INPUT Value

DOWN # Description Value

MANUAL CONTROL

SYSTEM MAIN MENU
IDLE
ESC
UPx11
MANUAL CONTROL MAN
SET+ESC
Menu enabled?
Show error
message
Yes No
Password required?
No Yes
Enter password
SET ESC
Password correct?
Show error
message
Yes No
EDIT
Manual Control
Value
On or Off
SET ESC
Revert back to old status
Switch manual control on or off

CONTROLLER MANUAL
STEAM / LTSF STERILZER
EMBEDDED CONTROL SYSTEM
User Manual
Ver 2.04
11th March 2005

CONTENTS
• Controller LED’s
• Variables
• Analogue Inputs
• Digital Inputs
• Digital Outputs
• Serial Port 4 – Display only, or Display and Printer
• Serial Port 3 – Printer only
• Calibration
• Manual Control
Controller LED’s
The three LED’s (L1, L2 and L3) on the front of the controller are used to make diagnostic procedures easier by indicating
some basic conditions and errors. See the tables below.
LED 1 DESCRIPTION
On Program is running.
Blinks Program is NOT running. Control has been returned to the operating system.
Possible causes:
• Program failed to start or encountered an unexpected condition that caused it to stop. To remedy
this restart the system by powering off and then back on.
• Program files missing or corrupt. The FLASH memory will need to be erased and then ALL the
program files must be loaded. Afterwards restart the system.
Off Operating system fault.
Possible remedies:
• System may need to be restarted, so power it off and then back on again.
• The wrong version of the BIOS may have been loaded. In this case the BIOS will need to be
replaced or upgraded.
LED 2 DESCRIPTION
On Power is good.
Off Power failure detected.
When this is detected the system will attempt to save certain critical parameters.
Possible causes:
• Power supply has been interrupted. Restore power to the system to continue running normally.
• Signal to power detection input is missing or faulty. Check the wiring to the power detection input
and repair as necessary.
LED 3 DESCRIPTION
On or Blinks Received a valid communication command from the computer software.
Off No communication from computer software or command was invalid.
If the computer software reports an error or no response is received from the controller then the
following are possible causes:
• The communication cable might not be connected correctly or properly. Make sure that it is
connected to the right serial port on the computer.
• The communication settings in the computer software may be incorrect. Check the selected serial
port, the baud rate, data bits, parity and stop bits settings.
• The communication cable might be damaged.

Variables
Below is a list of all the variable parameters:
# VARIABLE DESCRIPTION AND ACCEPTABLE VALUES TYPICAL MIN. MAX. Access

v00 Boiler blowdown time 2 min 0 min 10 min
(Note: Set this to 0 to disable boiler blowdown completely)
v01 Boiler level switches 2 1 2
v02 Automatic door operation No - -
v03 Jacket temperature high deviation limit 2 °C 0°C 999.9°C
v04 Jacket temperature low deviation limit 2 °C 0°C 999.9°C
v05 Boiler control temperature 129°C 0°C 199.9°C
v06 Boiler temperature high deviation limit 5 °C 0°C 999.9°C
v07 Boiler temperature low deviation limit 5 °C 0°C 999.9°C
v08 Printing interval during sterlize stage 1 min 0 10 hours
v09 Print date and time on reports Yes - -
v10 Power failure input state Off - -

When the input is in the same state it indicates an alarm condition.
For example: If this is set to off and the power fail input also goes
off, then the system will detect a power fail alarm. If the input goes
on the system will return to normal. However, if this is set to on and
the power fail input also goes on, then system detected a power fail
alarm. If the input goes off, the system returns to normal.
v11 Demineralised water level low input state On - -
v12 Vacuum pump water low input state Off - -
v13 Boiler water level low, lower input state On - -
v14 Boiler water level low, upper input state On - -
v15 Boiler overpressure input state Off - -
v16 Vacuum pump trip input state On - -
v17 Circulation pump trip input state Off - -
v18 Jacket overpressure input state Off - -
v19 Air pressure failure input state Off - -
v20 Door lock time 5sec 0sec 1hour

v21 Door unlock time 5sec 0sec 1hour
v22 Gasket inflate time 5sec 0sec 1hour
v23 Gasket release time 2min 0sec 1hour
v24 Vacuum break time for low pressure calibration 2min 1sec 1hour
v25 Automatic door timeout causes an error No - -
v26 Draw vacuum abort timeout 10min 0sec 10hours
(If this is 0sec then there will not be a timeout abort)
v27 Exhaust abort timeout 10min 0sec 10hours
v28 Steam pulse abort timeout 10min 0sec 10hours
v29 Steam inject abort timeout 15min 0sec 10hours
v30 Air admission abort timeout 10min 0sec 10hours


v31 Slow exhaust abort timeout 90min 0sec 10hours
v32 Maximum safe pressure to open automatic door 110kPa -100kPa 300kPa
If the chamber pressure is above this limit, the automatic door
will now be allowed to open.
v33 Boiler temperature high deadband 1.0 °C -99.99°C 99.99°C
v34 Boiler temperature low deadband 1.0 °C -99.99°C 99.99°C
v35 Jacket temperature high deadband 0.2 °C -99.99°C 99.99°C
v36 Jacket temperature low deadband 0.2 °C -99.99°C 99.99°C
v37 Boiler temperature control 1 0 2
0 = On/Off
1 = Deadband (v33 and v34)
2 = PID (v66, v67, v68 and v69)
v38 Jacket temperature control 1 0 2
0 = On/Off
2 = PID (v70, v71, v72 and v73)
v39 Number of samples to average for analogue inputs 4 1 99
v40 Chamber pressure rate of change limit 1000kPa/min 0 9999

v41 Sterilization low temperature alarm delay time 0sec 0sec 10min
This is the time that the sterilization temperature must be low
before the alarm switches on. Once the alarm is on, the
temperature must be OK for this period before the alarm switches
off.
v42 Sterilization temperature low deviation limit 0°C -99.99°C 99.99°C
v43 Chamber pressure high deadband (only for chamber temperature 0.02kPa -99.99kPa 99.99kPa
controlled by pressure)
v44 Chamber pressure low deadband (only for chamber temperature 0kPa -99.99kPa 99.99kPa
controlled by pressure)
v45 Chamber pressure alarm delay time 10sec 0sec 10min
The alarm will only switch on if the chamber pressure is outside
the limits for this period of time. Once the alarm is on, it will only
switch off once the pressure is within limits for this period of
time.
v46 Circulation pump runs continuously No - -
No = Circulation pump only runs during a cycle or while boiler is
being filled.
Yes = Circulation pump runs all the time.
v47 Boiler level alarm delay time 10sec 0sec 10min
This is the time that the boiler water level must be high or low
before the state of the alarm changes.
v48 Vacuum pump + Exhaust wait time 5sec 0sec 60sec
v49 Chamber temperature control by pressure Yes - -
No = The chamber temperature is controlled by monitoring the
chamber control input.
Yes = The chamber temperature is controlled by monitoring the
chamber pressure. The pressure setpoint is determined by
using a lookup table.
v50 Sterilant detection pressure change 3 kPa 0.01kPa 99.99kPa

v51 Temperature input configuration 2 0 10
RTD input module (i-87013)

0 = RTD Platinum 100 (Range: -100 to +100, ~0.00385)
1 = RTD Platinum 100 (Range: 0 to +100, ~0.00385)
3 = RTD Platinum 100 (Range: 0 to 600, ~0.00385)

8 = RTD Nickel 120 (Range: -80 to 100)
9 = RTD Nickel 120 (Range: 0 to 100)
NOTE: After changing and saving this value, the controller must
be switched off and then back on.
v52 Boiler temperature alarm delay time 10sec 0sec 10min
The temperature must be outside the high or low limits for this
period of time before the alarm will switch on. Once the alarm is
on, the temperature must stay within the limits for this period of
time before the alarm is switched off.
v53 Jacket temperature alarm delay time 10sec 0sec 10min
v54 Chamber temperature alarm delay time 30sec 0sec 10min
v55 Chamber high temperature alarm limit 140.0°C 0°C 999.9°C
If the temperature stays above this limit for the specified time,
then an alarm is raised and the steam valve is switched off.
v56 Chamber high pressure alarm limit 365.0kPa 0kPa 999.9kPa
If the pressure stays above this limit for the specified time, then
an alarm is raised and the steam valve is switched off.
v57 Chamber temperature control 1 0 1
0 = On/Off
2 = PID
v58 Chamber temperature high deadband 0 °C -99.99°C 99.99°C
This only applies when deadband temperature control is selected.
v59 Chamber temperature low deadband 0.1 °C -99.99°C 99.99°C
This only applies when deadband temperature control is selected.
v60 Buzzer cycle time 1min 0sec 10min

v61 Buzzer sterile/complete on time 5sec 0sec 10min
v62 Buzzer unsterile on time 1min 0sec 10min
v63 Number of samples to average for chamber pressure 8 1 99
v64 Steam Injection control temperature offset 0 °C -99.99°C 99.99°C
(This offset is added to the Steam Injection temperature to
determine the chamber temperature control setpoint. For example:
If the steam injection setpoint is 134 and this offset is 2, then the
chamber will be controlled at 136. However, the steam injection
stage still ends when 134, or greater, is reached.)
v65 Steam Injection Hold control temperature offset 0 °C -99.99°C 99.99°C
(This offset is added to the sterilizing temperature to determine the
chamber temperature control setpoint)
v66 Boiler temperature PID cycle time 3sec 1sec 10min
v67 Boiler temperature proportional band (P) 5°C 0°C 99.99°C
v68 Boiler temperature integral gain (I) 1 0 99.999
(Set this to 0 to disable the integral action)
v69 Boiler temperature derivative gain (D) 1 0 99.999
(Set this to 0 to disable the derivative action)
v70 Boiler temperature integral limit 100% 0% 100%

v71 Boiler temperature PID minimum output 0% 0% 100%
If the PID on duty cycle is below this limit, then it will be set to 0.
The output will only be switched on when the PID on duty cycle
is equal or higher than this limit. Therefore this is the minimum
duty cycle when the output is switched on.
v72 Boiler temperature PID maximum output 100% 0% 100%

The PID on duty cycle is clamped to this limit.
v73 Jacket temperature PID cycle time 3sec 1sec 10min
v74 Jacket temperature proportional band (P) 5°C 0°C 99.99°C
v75 Jacket temperature integral gain (I) 1 0 99.999
v76 Jacket temperature derivative gain (D) 1 0 99.999
v77 Jacket temperature integral limit 100% 0% 100%
v78 Jacket temperature PID minimum output 0% 0% 100%
v79 Jacket temperature PID maximum output 100% 0% 100%
v80 Initialize printer 0 0 2

0 = Never
1 = At the start of every report
2 = At the start of every report and before every printed line
v81 Printer connected to display Yes - -
Yes = Display is connected to COM4 on the embedded
controller. The printer is connected to the serial port on the
display.
No = Display is connected to COM4 on the embedded controller
and the printer is connected to COM3 on the controller.
v82 Print option (during cycle) 0 0 1
0 = Print at start of every stage and at intervals (v8) during the
setrilization stage.
1 = Print only a summary of the cycle and print at the specified
intervals (v8) during the sterilization stage.
v83 Print alarm values during cycle Yes - -
When this is “Yes” the value of the analogue input that caused the
alarm during a cycle will be printed.
v84 Show step number during cycle No - -
v85 Line feeds before report 3 0 9
v86 Line feeds after report 3 0 9
v87 Display refresh period 60sec 1sec 10min
Some displays need to be refreshed often, even when the text is
not changed.
v88 COM4 communications format 0 0 5
This must be exactly the same as the settings of the display. If the
printer is connected to the display, then the printer must be set the
same.
0 = No parity, 8 data bits, 1 stop bit
1 = Even parity, 8 data bits, 1 stop bit
2 = Odd parity, 8 data bits, 1 stop bit
3 = No parity, 7 data bits, 2 stop bits
4 = Even parity, 7 data bits, 2 stop bits
5 = Odd parity, 7 data bits, 2 stop bits
v89 COM3 communications format 0 0 5
If the printer is connected to this serial port, this setting must be
exactly the same as the settings of the printer. If the printer is
connected to the display this setting can be ignored.
0 = No parity, 8 data bits, 1 stop bit
1 = Even parity, 8 data bits, 1 stop bit
2 = Odd parity, 8 data bits, 1 stop bit
3 = No parity, 7 data bits, 2 stop bits
4 = Even parity, 7 data bits, 2 stop bits
5 = Odd parity, 7 data bits, 2 stop bits
v90 Display brightness 3 0 3

0 = 20%
1 = 40% or 50%
2 = 60% or 75%
3 = 100%
v91 Display emulation mode ESC/POS 0 4
0 = ESC/POS
1 = Noritake
2 = Futaba
3 = CD5220
4 = DSP-800
v92 Pressure engineering unit kPa 0 1
0 = kilopascal (kPa)
1 = millibar (mb)
v93 Date format 3 0 5
0 = DD / MM / YY
1 = MM / DD / YY
2 = YY / MM / DD
3 = DD / MM / YYYY
4 = MM / DD / YYYY
5 = YYYY / MM / DD
v94 COM4 baud rate 9600 bps 1200bps 115200bps
This must be exactly the same as the settings of the display. If the
printer is connected to the display, then the printer must be set the
same.
1.2 = 1200 bps
2.4 = 2400 bps
4.8 = 4800 bps
9.6 = 9600 bps
19.2 = 19200 bps
28.8 = 28800 bps
38.4 = 38400 bps
57.6 = 57600 bps
115.2 = 115200 bps
v95 Extraction fan time 10min 0sec 1hour
This is the time that the extraction fan will be switched on when
any of the doors are opened.
v96 Controller LED display intensity 0 0 15
0 is the lowest intensity and 15 is the brightest.
v97 Double door system No - -
No = Single door system
Yes = Double door system
v98 COM3 baud rate 9600 bps 1200bps 115200bps
If the printer is connected to this serial port, this setting must be
exactly the same as the settings of the printer. If the printer is
connected to the display this setting can be ignored.
1.2 = 1200 bps
2.4 = 2400 bps
4.8 = 4800 bps
9.6 = 9600 bps
19.2 = 19200 bps
28.8 = 28800 bps
38.4 = 38400 bps
57.6 = 57600 bps
115.2 = 115200 bps
v99 Autoclave ID number 0001 0000 9999
v100 Chamber temperature PID cycle time 3sec 1sec 10min

v101 Chamber temperature proportional band (P) 5°C 0°C 99.99°C
v102 Chamber temperature integral gain (I) 1 0 99.999
v103 Chamber temperature derivative gain (D) 1 0 99.999

v104 Chamber temperature integral limit 100% 0% 100%
v105 Chamber temperature PID minimum output 0% 0% 100%
v106 Chamber temperature PID maximum output 100% 0% 100%
v107 Chamber pressure PID cycle time 3sec 1sec 10min
v108 Chamber pressure proportional band (P) 5kPa 0kPa 99.99kPa
v109 Chamber pressure integral gain (I) 1 0 99.999
v110 Chamber pressure derivative gain (D) 1 0 99.999

v111 Chamber pressure integral limit 100% 0% 100%
v112 Chamber pressure PID minimum output 0% 0% 100%
v113 Chamber pressure PID maximum output 100% 0% 100%
v114 Automatic door open timeout 20sec 1sec 10min
v115 Automatic door close timeout 20sec 1sec 10min
v116 Sterilization temperature high deviation alarm delay time 0sec 0sec 10min
This is the time that the temperature must be high before the
alarm switches on. Once the alarm is on, the temperature must be
OK for this period before the alarm switches off.
v117 Sterilization temperature high deviation limit 0°C -99.99°C 99.99°C
Note that this alarm is only active during the following stages:
Sterilization, Steam Pulse, Steam Flush and Steam Injection.
Should this alarm remain on for the specified delay time (v116)
the stage will be aborted.
v118 Character code for the degrees C symbol on the display 143 0 255
(Consult display documentation for information about character
tables and codes. Some dip switches may need to be set to
support extended characters. To safely set this to a blank space on
all types of displays set this to 32.)
v119 Character code for the degrees C symbol in the printout 248 0 255
(Consult printer documentation for more information. To safely
set this to a blank space for all printers set this to 32.)
v120 Print power fail messages during a cycle No - -

v121 Print abort messages during a cycle No - -
If this is set to Yes all abort, hold, restart and resume events
during a cycle will be printed.
v122 Low water levels switch off jacket heating No - -
If this is set to No the water level does not affect the jacket
heating. If this is set to Yes a low water level will switch off the
jacket heating.
The embedded control system contains 250 variables. The above table lists the variables that have been assigned to specific
functions. (All variables not listed in the above table are reserved for future use.)
The typical values are for reference only and are for a high temperature steam machine with a single door.
There are 3 different access levels: Normal, Advanced and Engineer. The Normal and Advanced level variables can be edited
from the operator buttons. Engineer level variables can only be edited by using the computer software utility. (Note that the
access level of each variable can ONLY be changed with the software utility.)
To edit the variables from the operator buttons:

• While the machine is idle (displays the name of the selected cycle), press and hold the SET button for 5 seconds until the
main menu appears.
• Press the UP button until “NORMAL VARIABLES” or “ADVANCED VARIABLES” is selected.
• Press the SET button briefly.
• If asked for a password, use the UP or DOWN buttons to increase or decrease the password number. Press SET and UP at
the same time to increase the step size (the amount by which the password is increased or decreased). Press the SET and
DOWN buttons at the same time to decrease the step size. When finished press SET. (If the password entered is incorrect
an error message will be shown. Press any button to go back to the main menu.)
• Press UP or DOWN to scroll through the list of variables in the current access level.
• Press SET to start editing the value of the selected variable. Press UP or DOWN to increase or decrease the value of the
variable. Press SET and UP at the same time to increase the step size (the amount by which the password is increased or
decreased). Press the SET and DOWN buttons at the same time to decrease the step size. When finished press SET to
accept the new value.
• Press UP or DOWN to select the next variable to edit, or press ESC to go back to the main menu.
• Press ESC again to go back to idle mode. (If no key is pressed for 20 seconds in the Main menu, the system will
automatically go back to idle mode.)
To edit the variables from the setup/monitoring utility:

• Make sure that the communication cable is connected and make sure that no other software is using the serial port.
• Run the AC204 Setup software utility.
• Click on the Variables button.
• The current values can be retrieved from the embedded controller by clicking on the Read button.
• Click on the variable that must be changed.
• Now click on the value box and type or select a new value.
• When finished the new values must be sent to the controller by clicking on Write.
• To save the values to a file for record keeping purposes click on the Save File button, type a name for the file and click on
Save. The file can be opened at another time by clicking on the Open File button, selecting the file name and clicking on
Open.
• To send the variables in other software click on the Export button and then type a file name. The values will be saved in a
text file and the columns will be separated by tabs. It can be opened (or imported) by most word processors and
spreadsheet programs.

Analogue inputs
Analogue RTD input module (i-87013)
This module must always be installed in slot 1.
Module channel Analogue Input Description

0 Jacket temperature (°C)
1 Boiler temperature (°C)
2 Chamber control temperature (°C, for control and display)
3 Chamber monitor temperature (°C, for printing)
The type of inputs on this module are set by variable 51
Multimedia module with analogue voltage input (i-8073)

For i-8811 controllers this must be installed in slot 5.
For i-8411 controllers it must be in slot 3.
Module channel Analogue Input Description

VIN (0) Chamber pressure (mb or kPa)
The type of input for this module is always voltage and cannot be changed by software.
Monitoring the analogue inputs

To monitor the values of the analogue inputs:
• When the machine is idle (the name of the selected cycle is shown), press and hold the SET button for 5 seconds until the
main menu is shown.
• Press the UP button until “ANALOGUE INPUTS” is selected.
• Press SET.
• Use UP or DOWN to select an analogue input to monitor.
• When finished press ESC to go back to the main menu.
Note: When the software simulator is used the embedded control system will ignore the physical analogue inputs. The value of
all the analogue inputs will be read from the software simulator.

Digital inputs
16-Channel digital input module 1 (i-8051 non-isolated, or i-8053 isolated)
Note: This module is not required for single door systems.

For i-8811 controllers this must be in slot 3.
Module DIGITAL INPUT WIRE ALARM STATE

channel NUMBER VARIABLE
DI 00 Clean door close pushbutton
DI 01 Clean door open pushbutton
DI 02 Clean door fully closed limit switch
DI 03 Clean door fully open limit switch
DI 04 Spare
DI 05 Spare
DI 06 Spare
DI 07 Spare
DI 08 Spare
DI 09 Spare
DI 10 Spare
DI 11 Spare
DI 12 Spare
DI 13 Spare
DI 14 Spare
DI 15 Spare
16-Channel digital input module 2 (i-8051 non-isolated, or i-8053 isolated)


DI 00 Dirty/Single door close pushbutton
DI 01 Dirty/Single door open pushbutton
DI 02 Dirty/Single door fully closed limit switch
DI 03 Dirty/Single door fully open limit switch
DI 04 Start cycle pushbutton
DI 05 Select cycle pushbutton
DI 06 Power fail v10
DI 07 Vacuum pump overload v16
DI 08 Circulation pump overload v17
DI 09 Jacket overpressure switch v18
DI 10 Air pressure switch v19
DI 11 Boiler pressure switch v15
DI 12 Boiler low level switch v13
DI 13 Boiler fill level switch v14
DI 14 Demineralized water level switch v11
DI 15 Vacuum pump water level switch v12


DI 00 Menu Set pushbutton
DI 01 Menu Exit pushbutton
DI 02 Menu Up pushbutton
DI 03 Menu Down pushbutton
Monitoring the digital inputs

The state of the digital inputs are indicated by LED’s on the modules to simplify diagnostic procedures.
To monitor the values in the embedded control system:

main menu is shown.
• Press the UP button until “DIGITAL INPUTS” is selected.
• Press SET.
• Use UP or DOWN to select a digital input.
Notes
Spare inputs are reserved for future use and should not be connected.
Note: When the software simulator is used the embedded control system will ignore the physical digital inputs. The state of all
the inputs will be read from the software simulator.

Digital outputs
16-Channel digital output module 1 (i-8056 non-isolated, or i-8057 isolated)

Module DIGITAL OUTPUT WIRE NUMBER

channel
DO 00 Dirty/Single door close
DO 01 Dirty/Single door open
DO 02 Dirty/Single door lock
DO 03 Dirty/Single door unlock
DO 04 Dirty/Single door gasket inflate
DO 05 Dirty/Single door gasket deflate
DO 06 Bleed valve
DO 07 Steam to chamber valve
DO 08 Air valve
DO 09 Exhaust valve
DO 10 Circulation pump
DO 11 Vacuum pump
DO 12 Jacket steam valve or heating element
DO 13 Boiler heating elements
DO 14 Boiler fill valve
DO 15 Boiler blowdown
16-Channel digital output module 2 (i-8056 non-isolated, or i-8057 isolated)
This module is not required for a single door system.


channel
DO 00 Clean door close
DO 01 Clean door open
DO 02 Clean door lock
DO 03 Clean door unlock
DO 04 Clean door gasket inflate
DO 05 Clean door gasket deflate
DO 06 Doors locked lamp
DO 07 In progress lamp
DO 08 Cycle complete lamp
DO 09 Fault lamp
DO 10 Spare
DO 11 Spare
DO 12 Spare
DO 13 Spare
DO 14 Spare
DO 15 Spare


channel
DO 00 Audible alarm
DO 01 Extraction fan
DO 02 Sterilant fill valve
DO 03 High temperature steam valve
Monitoring the digital outputs

To monitor the values of the digital outputs:
main menu is shown.
• Press the UP button until “DIGITAL OUTPUTS” is selected.
• Press SET.
• Use UP or DOWN to select a digital output.
Notes
Spare outputs are reserved for future use and should not be connected.
When the software simulator is used all the physical digital outputs are switched off. All output functions will only be simulated
and the state of the virtual outputs can bee seen in the software simulator.

Serial port COM 4 – Display or Display+Printer
This port can be connected to a display, or a display and a serial printer. Different baud rates are selectable from 1200bps to
115200 bps by changing the appropriate variable. The standard cable for a serial display is as follows:
DISPLAY
i-8000
COM4 CN5
COM4 Mylar Screened DISPLAY

9-way D-type 4000mm 25-way D-type
Female WIRE COLOR Male
Transmit 3 Red 3 Receive
Ground 5 Blue 7 Ground
DSR 6 Yellow (not required) 20 DTR
The printer can be connected to the display in a pass-through configuration (if the display supports it). It is necessary for the
printer to be configured for the same baud rate and communication format as the display.
The standard cable is as follows:
DISPLAY PRINTER
CN5 CN3
DISPLAY Mylar Screened PRINTER

9-way D-type 600mm 25-way D-type
Female WIRE COLOR Male
Transmit 3 Red 3 Receive
Ground 5 Blue 7 Ground
DSR 6 Yellow 20 DTR

Two displays can be connected with the appropriate cable as shown below: (Printer can be connected to either of both of the
displays in a pass-through configuration as shown above)
DISPLAY 1 DISPLAY 2
i-8000
COM4 CN5 CN5
Y-Splitter cable: ( x1 )
COM4 Mylar Screened Y-Splitter

9-way D-type 1500mm 2 x mini-DIN
Female WIRE COLOR Female
Transmit 3 Green
Ground 5 Black
Display interface cable: ( x2 )
From Y-splitter Mylar Screened Display

6-way mini-Din 1200mm 25-way D-type
Male WIRE COLOR Male
Receive Green 3
Ground Black 7
Serial port COM 3 - Printer
This port can be connected to a serial printer if the display does not support a pass-through connection with the printer.
Different baud rates are selectable from 1200bps to 115200bps by changing the appropriate variable. The standard cable for a
serial printer is as follows:
COM3 PRINTER
9-way D-type 25-way D-type
Female Male
Transmit 2 3 Receive
Ground 5 7 Ground

Calibration
The calibration can be done from the operator menu buttons as follows:
main menu appears.
• Press the UP button until ANALOGUE CALIBRATION is selected.
• Press the SET button briefly.
• If asked for a password, use the UP or DOWN buttons to increase or decrease the password number. Press SET and UP
at the same time to increase the step size (the amount by which the password is increased or decreased). Press the SET and
DOWN buttons at the same time to decrease the step size. When finished press SET. (If the password entered is incorrect
an error message will be shown. Press any button to go back to the main menu.)
• Press UP or DOWN to scroll through the list of analogue input calibration procedure.
Next, follow the procedure that corresponds to the selection:
Low temperature calibration
• Place the temperature sensor in a cold medium along with an accurate thermometer.
• Press SET and ESC at the same time. It will now show the previous calibration value on the display.
• Wait for the temperature to stabilize and then take a reading on the thermometer.
• Use the UP or DOWN buttons to enter the new temperature reading.
• When finished press SET to complete the calibration, or ESC to abort. NOTE: If the temperature changes while the
value is being entered (before SET is pressed) wait for it to stabilize again, take a new reading and enter the new value.
High temperature calibration
• Place the temperature sensor in a hot medium along with an accurate thermometer.
• Wait for the temperature to stabilize and then take a reading on the thermometer.
• Use the UP or DOWN buttons to enter the new temperature reading.
• When finished press SET to complete the calibration or ESC to abort. NOTE: If the temperature changes while the value
is being entered (before SET is pressed) wait for it to stabilize again, take a new reading and enter the new value.
Pressure Calibration
Each analogue channel has 2 calibration setpoints and both must be calibrated correctly. For the temperature channels the first
setpoint is calibrated at low temperature and the second one at high temperature. However, the pressure channel has more
options. Both setpoints can be calibrated at a vacuum, atmospheric or high pressure.
Below is a table that will help to identify the different options:

Display LED Description
display
Chamber Pressure 4 V1 Setpoint 1 will be calibrated at a vacuum. The system will lock and seal the door(s)
Vaccum Cal 1 and then draw a vacuum.
Chamber Pressure 4 V2 Setpoint 2 will be calibrated at a vacuum. The system will lock and seal the door(s)
Vacuum Cal 2 and then draw a vacuum.
Chamber Pressure 5 P1 Setpoint 1 will be calibrated at atmospheric or high pressure.
Pressure Cal 1
Chamber Pressure 5 P2 Setpoint 2 will be calibrated at atmospheric or high pressure.
Pressure Cal 2
NOTE: Both setpoints cannot be calibrated at the same pressure, for example both at 100kPa. There must be a difference
in the actual pressures for the system to be able to scale this channel correctly. It is recommended that the setpoints are

calibrated at pressures where the system will operate. For example: Setpoint 1 may be calibrated at vacuum and setpoint 2
at atmospheric. Or setpoint 1 could be calibrated at atmospheric and setpoint 2 at high pressure. Or setpoint 1 may be
calibrated at vacuum and setpoint 2 at high pressure. Consider the operation and the implications of the pressure
calibration carefully before choosing an option.
See the sections below for more information on each option:
Vacuum pressure calibration
• Place a pressure gauge in the chamber.

• A prompt will be shown to close the door(s) if it open.
• When the door is closed the system will attempt to lock the door, inflate the seal and then draw a vacuum.
• Wait for the vacuum to stabilize.
• Take an accurate reading by using the pressure gauge.
• Use the UP or DOWN buttons to enter the new pressure reading.
• When finished press SET to complete the calibration or ESC to abort. NOTE: If the pressure changes while entering the
value (before SET is pressed) wait for the pressure to stabilize again, take a new reading and enter the new value.
• The system will admit air into the chamber for a period of time and then release the seal and unlock the door.
Atmospheric pressure calibration
• Make sure that the chamber pressure sensor is at atmospheric pressure.

• Wait for it to stabilize and then take an accurate reading by using a pressure gauge.
• Use the UP or DOWN buttons to enter the new atmospheric pressure reading.
High pressure calibration
• Attach a pressure gauge and high pressure supply to the pressure sensor.
• Feed a high pressure into the sensor.
• Wait for it to stabilize and then take an accurate reading.
• Use the UP or DOWN buttons to enter the new pressure reading.
Manual Control
Manual control allows the operator to step forward or back through the steps of a cycle. While manual control is switched on
the normal end of step conditions (for example time or temperature reached) does not apply. The cycle will wait in each step
until the operator presses a button. The UP button will continue to the next step, while the DOWN button will go back to the
previous step.
While the machine is idle the display will flash the name of the selected cycle and the words “manual control” alternatively to
indicate that manual control has been switched on. If only the name of the cycle appears it indicates that manual control is
switched off.
Note: Manual control cycles are always considered unsterile and this condition is set at the start of the cycle. The words
“Manual control” will also be printed below the name of the recipe on the printout when a cycle is started.
To switch manual control on or off:

• While the machine is idle press and hold down the SET button for 5 seconds until the maain menu appears.
• Press the DOWN button repeatedly until “Manual control” is shown.
• Press SET and ESC at the same time.
• If prompted for a password use the UP and DOWN button to enter it and press SET to continue.
• Press the UP or DOWN buttons to switch manual control on or off.
• Press SET to accept it and return to the main menu. Or press ESC to abort and return to the main menu.

ENGINEERING SOFTWARE MANUAL
I-8000 EMBEDDED CONTROLLER
STERILIZER VERSION 2
Setup/Monitoring Utility Operator Manual
CONTENTS
• Main menu
• First time configuration
• Variable names
• Error names
• Cycle step names and configuration
• Information and status
• Date and Time
• Variable values
• Variables access levels
• Log to file
• Pressure lookup table
• Calibration
• Menu passwords
• Cycle recipe setup
• Cycle number
• Door status
• Manual Control
• Communication errors
• Token file
• Configuration files

Main Menu
If a shortcut to this software utility is available on the desktop run it be double-clicking on the shortcut icon. If there is
no shortcut, click on the Start menu, click on Programs, click on the name of the utility, AC204 Setup, and then click on
its name in the menu that opens.
As soon as the software starts it will show the main menu.
Main menu
To close the software simply click on the X in the top right-hand corner, or click on the Exit button and confirm by
clicking Yes.
Note: The software only uses the serial port when it needs to. As soon as it is finished it releases control of the serial
port back to the operating system. This means for example that while this software is in the main menu other software
can be opened that uses the same serial port. However while this software is busy communicating, for example in the
Log File menu or the Info menu, the serial port cannot be used by other software.
First-time configuration
The first time that the software is run after it has been installed on a new computer system certain of the parameters and
options need to be configured correctly for the software to function properly.
First the serial communication parameters must be set correctly. Click on the “Comms. Setup” button in the main menu.
It is illustrated below.
Serial Communication Setup

Make sure that the serial port is set correctly. This is the serial port on the computer where the cable will be connected
to communicate with the embedded controller. Normally this will be COM1. However, if another device is already
connected to this port (like a mouse) then it must be changed to COM2 or COM3. In general the serial ports on most
computers are marked with number so it should be easy to determine which serial port will be used.
The selection boxes for the baud rate, data bits, parity and stop bits are disabled. These settings are fixed and cannot be
changed.
The timeout setting determines how long the software will wait when it receives no response before it tries again. The
normal setting is 0.3 seconds and if this is set too short all communication will fail. The number of tries sets the
maximum number of times that the software will send the same request/command before aborting communication. If a
response is received on the first try the software will go to the next request/command. However if a timeout occurs
because no response is received the software will try to send the same request/command again if this setting is 2 or
more. This will be repeated until a valid response is received or until the request/command has been sent the same
number of times as this setting at which time the software will abort communication. Normally this settings can be set
on 5. If random communication errors occur then this number can be increased to try and overcome the problem.
To save and apply the new settings click OK. It will return to the main menu.
Second, the general options must be set. Click on the “Settings And Options” button in the main menu. It is shown
below.
General Settings and Options
The first options sets the engineering unit of pressures (kPa or mb) in this software only. (Note that this option does not
affect the embedded controller. To change the way that the embedded controller displays and prints pressures the
appropriate variables must be modified.)
The second option determines the interval that data will be recorded to a log file when the Log File function has been
selected.
Click on OK to save the new settings and go back to the main menu.

Variable names
Menus in this software and also in the embedded controller display or print the names of variables. Therefore it is
necessary to setup the names correctly before using the software. The software automatically sets the names to the
factory defaults the first time it is run. If any of the names or engineering units of the variables have been changed it is
necessary to edit the variables in this menu.
Click on the “Variable Names” button in the main menu.
Variable Names and Engineering Units
Click on a variable to highlight it. Now click on the “Edit Name” button. Type the name that will appear in this
software, type the short name for the embedded controller and then select the engineering unit. Click OK to apply the
changes. Repeat this for all the variables that must be changed.
Edit Variable Names and Engineering Unit
To send the new names of the variable to the embedded controller click on Write. This will take a few seconds. This
must be done for all new embedded controllers since their table of variable names is blank.
The list of names can be exported to a text file by clicking on Export. The text file can be opened with most word
processing or spreadsheet programs.
To print the list of names click on the Print button. Note: The printing routine will not print variables with blank names.
It reduces the number of pages that will be printed because a blank name would indicate that a variable is not used for
any function.
Close this window when finished. At this point the software will save all changes that have been made.
The names and engineering units of the variables are saved in a file called “VarName.ini” that can be found in the same
folder where this software is installed. To update the list of variables on another computer copy this file to that
computer. Make sure that this software is not running when copying the file. When asked to overwrite the file on the
destination computer click Yes.

Error Names
The names of errors shown in the Information menu can be edited to allow for future expansion and changes. The same
names are also used by the software simulator.
Click on the “Error Names” button in the main menu.
Error Names
The software allows up to 32 names to be defined. Edit the names and then click OK to save the changes.
The list can be exported to a text file by clicking on the Export button. Or print it by clicking on Print.
The names are stored in a file called “ErrName.ini”. To update the names on another computer copy this file to that
computer. This file should also be copied to the same folder as the software simulator to update that software.
Cycle Step Names and Settings

The names and configuration of the cycle steps can be edited to allow for future changes and additions. Click on the
“Step Types” button in the main menu.
List of Cycle Step Names
To add new steps click on the Add New button. To edit an existing step highlight it and then click on Edit. Or click on
Delete to remove the highlighted step. When finished click Close to save the changes.
The step editing box is shown below.

Edit Step Name and Settings
Type the name of the cycle step. Type the function code. (The function code must correspond to the function code in the
embedded control software.) Select the engineering unit and set options that determine whether the main parameter and
the abort step are shown or not. Select the type of step. The type of step is important because it determines how the
software displays this step, it also determined how other parameters in the cycle recipe will be treated.
When finished click OK to accept the changes and go back to the list of steps.
NOTE: Changes to the names or configuration of the steps do NOT affect the embedded controller. Any changes to the
steps must be reflected in the embedded software by editing the source code and recompiling it.
The cycle step configuration is stored in a file called “StepName.ini”. This file should be copied to other computer to
update them. It should also be copied to the software simulator, since it uses the same list of step names.
Information and Status

Make sure that the embedded controller is powered up and that the communication cable is connected. In the main
menu click on the Info and Status button to open this window. The window is shown below.
Figure 4 – Info and Status window
The status of the embedded control system can be monitored from here. (Note that while this window is shown the
serial port is controlled by this software and cannot be used by other software.)
In this window the software version of the embedded control system is shown along with the machine and cycle
numbers. The name of the cycle, the name of the running cycle step and the step time is also shown. At the bottom the
states of the alarms are shown.
The names in the list of alarms and the name of the current cycle step can be edited with this software. See the
appropriate sections for more information.
Click on the Close button to return to the main menu.

Date and Time
Click on the Date and Time button in the main menu
Figure 5 – Date and Time window
Make sure that the embedded controller is powered up and that the communication cable is connected. To check the
date and time in the embedded controller click on the Read button. If it was successful the text boxes will show the date
and time in the embedded controller when it responded to this request.
To adjust the date and time in the embedded controller, first enter the correct values in the text boxes and then click on
Write.
To set the date and time to the same as the computer system click on Copy to copy the current computer date and time
to the text boxes. Then click on Write to send the date and time to the embedded controller.
When finished click on Close to return to the main menu.
Variables Values
In the main menu click on the “Variable Values” button. The menu is shown below.
List of Variables Values
Click on a variable to highlight it. Below the list the number, name and value of the selected variable will be shown.
Type or select the new value of the variable. Repeat this for all the variables that need to be changed.
When finished store the values by clicking on the Save File button, type a name for the file and then click the Save
button. This allows the values to be stored for backup or record keeping purposes. Values that were previously saved
can be recalled by clicking on the Open File button, select the correct file and then click the Open button.
Note that the variables are edited offline. This means that the software does not use the serial port or try to communicate
with the embedded controller while the variables are being edited. Only when the Read or Write buttons are clicked
does the software communicate with the controller. Therefore the embedded controller must be powered up and
connected to the computer before clicking on Read or Write.
To read the values from the embedded controller click Read. To send the new values to the embedded controller click
Write.

The list of variables and their values can be exported to a text file or printed. To set all the values to 0 click on Clear
All.
The name and engineering unit of the selected variable can be changed by clicking on Edit Name. (This option may be
disabled depending on the token file)
When finished click Close to go back to the main menu. (Note: The software automatically remembers the last values
and will show them the next time this menu is opened.)
Variables Access Levels

In the main menu click on the “Variable Levels” button. The menu is shown below.
List of Variables Access Levels
Click on a variable to highlight it. Below the list the number, name and access level of the selected variable will be
shown. Select the new access level of the variable. Repeat this for all the variables that need to be changed.
The access level determines if operators have access to variables in the embedded controller. Normal and Advanced
variables will appear in the Normal Variables and Advanced Variables menus in the controller. These can be edited
from the buttons. Access to these menus can also be restricted with a password. Engineering variables cannot be edited
or accessed from the buttons. They can only be changed by using this software.
When finished store the data by clicking on the Save File button, type a name for the file and then click the Save button.
This allows the data to be stored for backup or record keeping purposes. Data that were previously saved can be recalled
by clicking on the Open File button, select the correct file and then click the Open button.
Note that the variables are edited offline. This means that the software does not use the serial port or try to communicate
with the embedded controller while the variables are being edited. Only when the Read or Write buttons are clicked
does the software communicate with the controller. Therefore the embedded controller must be powered up and
connected to the computer before clicking on Read or Write.
To read the data from the embedded controller click Read. To send the new data to the embedded controller click Write.
The list of variables and their access level can be exported to a text file or printed. To set all the levels to Normal click
on Clear All.
The name and engineering unit of the selected variable can be changed by clicking on Edit Name. (This option may be
disable in the token file)
When finished click Close to go back to the main menu. (Note: The software automatically remembers the last values
and will show them the next time this menu is opened.)

Log To File
The controller must be powered up and connected to the computer. In the main menu click on the Log To File button.
Log To File window
This window will show the current date and time in the embedded controller. It will also show the running step name
and the temperatures and pressure. Note that while this window is shown the software takes control of the serial port
and no other software can use it.
To record the data to a text file click on the Start button, type a name for the file and the click on the Save button. The
software will now continuously monitor the controller and record the information to a text file at the interval specified
by the general options. The columns in this text file are separated by tab characters and it can be opened by most word
processor or spreadsheet programs.
To end the recording click on the Stop button.
Pressure Lookup Table

In the main menu click on the Pressure Lookup button.
Pressure Lookup window
The embedded control system can be configured (by setting the appropriate variables) to control the chamber
temperature by using a steam pressure lookup table. The setpoints in the table can be edited in this window. Up to 200
setpoints are allowed. Setpoints that are not used should be set to 0°C and 0kPa and should be placed at the end of the
list. All setpoints should be in numerical order with lowest setpoints at the top of the list and the highest setpoint at the
bottom.

To edit a setpoint, first click on it to highlight the row, then type the new values in the temperature and pressure boxes
at the bottom.
The lookup table can be stored by clicking on the Save File button, typing a name for the file and clicking Save. This
allows the values to used for other identical systems without the need for typing them all over again.
Values that were stored previously on the computer can be opened by clicking on Open File, selecting the correct file
and then clicking the Open button. The list will now show the values that were read from the file.
The values can be read from the embedded controller by clicking the Read button. To send new values to the controller
click the Write button.
Click on Clear All to set all the temperatures and pressures in the lookup table to 0.
The values can be saved to a text file for other word processing or spreadsheet programs. Click on the Export button,
type a name and then click on Save.
When finished click on Close to return to the main menu. (Note: The software remembers the last values before this
window was closed. When this window is opened again it will show those values.)
Calibration
The embedded controller must be powered up and connected to the computer. In the main menu click on the Calibration
button. The new window is shown below.
Calibration window
Note: While this window is open the software controls the serial port and no other software can use it.
In this menu the software monitors the analogue inputs on the embedded controller. In the first 2 columns on the left the
current device values and actual values are shown. Device values come directly from the analogue to digital conversion
hardware and can be in volts, milliamps or bits. Actual values are the scaled engineering value that is represented by the
device values and they have meaning to the operator of the system. For example: A device value of 2 volts might
represent an actual value of 83°C. The embedded control system uses a linear scaling function to convert the device
values into actual engineering values. This method uses two sets of setpoints – Device 1 and Actual 1 is the first set, and
Device 2 and Actual 2 is the second set. For example: Device 1 might be 25000 and that represents 26.1°C in Actual 1.
The second set must be at a different point (for example colder or hotter). For example: Device 2 might be 50000 and
that represents 132°C in Actual 2.
The reason for software calibration is simply that no two sensors are exactly the same, so the software calibration can be
used to compensate for this. Further, any conditioning and amplifying hardware connected to the sensors will change
the signal levels that the controller sees. Software calibration also allows different types of sensors to be used and when
replacements need to be made it allows for quick and easy adjustments.
One way to perform a temperature calibration would be to place the sensor in a medium that is at room temperature
along with an accurate thermometer. Watch the readings in the first column on the left and wait for it to stabilize. Now
type what is in the first column (Device) into the third column (Device 1). Take a reading from the thermometer and
type the temperature into the fourth column (Actual 1). Now place the sensor and the thermometer into a very hot
medium and again wait for the readings to stabilize. Type what is in the first column (Device) into the fifth column

(Device 2). Type the temperature read from the thermometer into the sixth column (Actual 2). Repeat all these steps for
each of the temperatures. For the pressure channel use a low pressure for the first steps and then use a high pressure for
the last steps.
The values can be stored on the computer by clicking Save File, typing a name and then clicking the Save button. This
allows backups to be made. Values that were previously stored can be open by clicking Open File, selecting the correct
file and clicking Open.
The calibration values that are currently in the embedded controller can be read by clicking on the Read button. After
the values have been adjusted and calibrated correctly they can be written to the embedded controller by clicking on
Write.
To save the values to a text file click on Export, type a name and then click on Save. The newly created file can be
opened by most word processor or spreadsheet programs.
Password Setup
In the main menu click on the Password Setup button. The new window is shown below.
Password Setup
Certain of the menus in the embedded control system can be protected by passwords to restrict access to them. The
passwords must be numbers in the range from 0 to 99999. The number 0 is special since it allows unrestricted access to
a menu. This means that any operator can access that menu without entering a password. The number 99999 is also
special and makes a menu completely inaccessible to all operators. Any other number (1 to 99998) means that the
operator will be prompted for a password before being granted access to a menu. For example if the number 5 is chosen
for the password to the Advanced Variables menu. When the operator chooses that menu on the controller, he/she will
be prompted for a password and will have to type 5 and press Enter before being allowed to continue.
The list of passwords can be stored on the computer by clicking Save File, typing a name for the file and then clicking
Save. Previously saved passwords can be opened on the computer by clicking Open File, selecting the file and clicking
Open.
The passwords that are in the embedded controller can be read by clicking the Read button. New passwords can be
written to the controller by clicking Write. Before clicking Read or Write the controller must be powered up and
connected to the computer.
The passwords can be saved to a standard text file by clicking Export, typing a name and then clicking Save.
To change all the passwords to 0 click on Clear All.
Click Close when finished to return to the main menu.

Cycle Recipe Setup
In the main menu click on the Cycle Recipe Setup button. The two pages in the this window is shown below.
Cycle Recipe Setup and List of Steps
Cycle recipes are edited offline which means that the software does not use the serial port and the controller does not
need to be connected. However, before the Read or Write buttons are clicked the embedded controller must be powered
up and connected to the computer.
In this window the main parameters and the steps of each cycle recipe can be set. The first page contains the cycle name
and the main parameters. The second page contains a list of all the steps in the cycle. The controller can contain up to
20 cycle recipes and each one can have a maximum of 50 steps.
The Cycle Name is the name that will appear on the display and the printout when that cycle is selected. The name may
contain any off the standard characters and may be uppercase or lowercase. Its length is limited to 20 characters.
If Cycle Enable option is switched on (ticked) the operator can select and run this cycle. If this option is switched off
(blank) the operator cannot select or run this cycle.
The “Add sterilizing temp to name” option determines whether the sterilizing temperature will be added to the above
cycle name when it is shown or printed. For example in the above illustration this option is switch on, so the name that
will be shown and printed is “LTSF 50°C”.
The next parameter sets the Jacket Control Temperature. The control system will attempt to maintain the jacket at this
temperature. The next three parameters set the Sterilizing Temperature, Timeout and Type of Abort. These parameters
have no affect if the cycle has no sterilizing step. The next parameter is the Leak Test Rate. This has no effect if the
cycle does not contain a leak test step.
The type of cycle determines if this is a high temperature steam cycle or if it is a LTSF cycle.
The “Successful door enabled” option selects which door will be enabled at the end of the cycle if it is successful or
sterile. The next option “Unsterile door enabled” selects which door will be enabled at the end of the cycle if it is
unsuccessful or unsterile. This allows standard and passthrough cycles to be created.
The second page shows all the steps in the cycle. To add new steps click on the Add button. Select a position for the
new step and then click Ok. This is shown below.

Select position for new cycle step
Now the step editing window will be shown as illustrated below.
Edit the Cycle Step
The drop-down box is used to select the type of step. The second box is the parameter for this step. Depending on the
type of step this could be a time, a temperature or a pressure. (Note: Some steps do not require a parameter and
therefore this box may not be visible) The last box at the bottom is used to select the abort destination for this step. As
more steps are added to the cycle the abort list will show the names of the steps making it easier to select an abort step
number. (Note: Some steps cannot be aborted and this box may therefore not be shown) If the abort step number is 0 or
the same as the step number then this step cannot be aborted. If the number is greater than the number of steps in the
cycle, the cycle will end if this step is aborted.
When finished click OK to accept the new values and add this step to the list.
An existing step can be edited by clicking on it and then clicking on the Edit button. To delete a step, first highlight it
by clicking on it and then click the Delete button. The highlighted step can be moved up or down in the list by clicking
the Up or Down buttons respectively.
When finished editing the cycle recipe it can be stored on the computer by clicking Save File, typing a name and then
clicking Save. This allows backups and also makes setting up other systems easier and quicker since the same recipe
does not have to be re-created each time. To open previously stored recipes click on the Open File button, select the
correct file and then click on Open.
A cycle recipe can be read from the embedded controller by clicking the Read button. Select a recipe number from 1 to
20. Click the Read Names button to request the names of all the recipes from the embedded controller. When the cycle
has been highlighted click Ok to continue.
Figure 14 – Select cycle recipe number
Cycle recipes can be written to the embedded control by clicking on Write. Select a recipe number and then click Ok.
Note: If another recipe is already stored at the selected recipe number it will be overwritten.

The recipe can be saved to a text file by clicking on the Export button, typing a name and then clicking Save. The file
can be opened by most word processors and spreadsheet programs.
Cycle Number
In the main menu click on the “Cycle Number” button. The new menu is shown below.
Cycle Number
Make sure that the embedded controller is powered up and connected to the computer before clicking on Read or Write.
Click on Read to read the next cycle number from the embedded controller.
Type a new number in the text box and click Write to set the next cycle number in the embedded controller.
Click on Close to go back to the main menu.
Door Status
In the main menu click on the “Door Status” button.
Door Status
This menu might not be available depending on the token file. This menu should only be used for maintenance
purposes.
On a single door machine the settings in this menu has no effect. On a double door machine it sets the status, enabled or
disabled, for both doors. It could be used to enabled one or both doors for maintenance.
Click Read to get the current status of the doors from the embedded controller. Click Write to send the new door status
to the controller.

Manual Control
In the main menu click on the “Manual Control” button:
Manual Control
This menu may not be enabled depending on the token file. Manual Control should only be switched on for
maintenance or special testing purposes. Note: Manual control can be switched on or off while a cycle is in progress so
this function must be used with great care.
Click Read to see the current status of the machine.
Select on or off and then click Write to update the manual control status of the machine.
Serial Communication Errors
The following are the most common errors that may be shown: (The error messages will only be shown when the
software tries to access the serial port and communicate with the embedded controller.)
• Error 8002: Invalid port number

The selected serial port does not exist on the computer. For example: The computer might only have 2 serial
ports, COM1 and COM2, but COM4 has been selected. To correct the problem simply select a port that does
exist.
• Error 8005: Port already open

Other software is already using the serial port. Close the other software and then try again. Or select another
serial port that is not used by any other software or hardware.
• Failed to read or write a parameter (The actual message will be different and will contain the name of the
parameter that caused the error)
This error is normally caused when the embedded controller is not connected correctly to the computer, or it is
not powered up. Also make sure that the correct serial port is selected.

Token file
The token file enables the functions of this software. Without a token file all the functions will be disabled. Token files
have the extension .tok and are generated and edited with the AC204 Token utility. If any or all of the buttons in the
main menu is disabled it means that those functions are disabled in the token file or no token file is present.
The software will search for a token file in the same folder where it is installed. (By default this is C:\AC204 Setup) It
will open the first token file it finds.
See the appropriate documentation for more information.
Configuration files
Certain of the configuration files contain names and other settings that may need to be copied to other computers to
update them. Some of these files are also used by the software simulator.
Variable Names (VarName.ini)
This file is only used by the AC204 Setup software and can be edited as described earlier in this document. If the names
or engineering units of the variables are changed or if new one are added this file should be copied to the other systems
to update them as well. The first time the software is run it will create this file and fill it with the default information.
Error Names (ErrName.ini)
This file is used by both the AC204 Setup and the AC204 Sim software. If the names of the errors in the simulator
software is blank or incorrect then this file must be copied to the same folder.
Cycle Step Names (StepName.ini)
This file is used by the AC204 Setup and the AC204 Sim software. If the names of steps are incorrect, blank or
“unknown” then this file must be updated.
Digital I/O Names (Digital.ini)
This file is only used by the AC204 Sim software. It is automatically created and filled with default names for the inputs
and outputs the first time the software is run. Use a text editor or wordprocessor to edit this file if necessary. The next
time the software simulator is run the changes will take effect.
To copy any of the above files to disk:
• Close the AC204 Setup or AC204 Sim software if it is running.

• Open Windows Explorer or My Computer.
• Find the “C:\AC204 Setup” or “C:\AC204 Sim” folder and double-click on it. (Select the one with the most up to
date and correct information)
• Click on the Edit menu and click Copy.
• Insert a blank disk.
• Find the disk drive (normally A: or B: ) and double-click on it.
• Click on the Edit menu and click Paste.
• Wait for the copying to finish.

To copy the above files from a disk:
• If the AC204 Setup or AC204 Sim software is running close it.

• Insert the disk containing the file(s).
• Find the disk drive (usually A: or B: ) and double-click on it.
• Click on the file to highlight it.
• Find the destination folder and double-click on it. (The destination should be “C:\AC204 Setup” or “C:\AC204
Sim”)
To copy any of the above file from AC204Setup to AC204Sim (simulator):
• If the AC204 Setup or AC204 Sim software is running close them.

• Find the “C:\AC204 Setup” folder and double-click on it.
• Click on the file that you want to copy. (for example: ErrName.ini)
• Find the “C:\AC204 Sim” folder and double-click on it.

ENGINEERING SOFTWARE INSTALLATION
I-8000 EMBEDDED CONTROLLER
STERILIZER VERSION 2
Setup/Monitoring Utility - Installation
Installing the software

1. Create a folder in the root directory of your laptop or PC and call it STERIDIUM
SETUP and copy the autoclave setup files to this folder.
2. Change the name of the file SETUP-COPY.EX_ to SETUP.EXE. The file type should
now change from an .EX_ type to an APPLICATION type.
3. Open the folder on your laptop or PC to view the files and run (double click) the
SETUP (88 KB application file).
4. Click on the INSTALL icon and the programme installation will be performed. The
programme AC204Setup (922 KB application file) will be installed in the directory
C:\AC204Setup. A program shortcut AC204Setup v2.04 will also have been
created.
5. Copy the file User1.tok from the STERIDIUM SETUP folder to the C:\AC204Setup
folder.
6. The programme can now be run by clicking on the program shortcut

AC204Setup v2.04
Connecting to the controller.

1. Ensure that the controller is switched off when plugging in the laptop or PC.
2. Connect the PC or laptop to the controller using a standard RS232 cable. If the PC or
laptop only has USB ports and does not have a serial port, a USB/RS232 adaptor will
be required.
3. Plug the cable into the COM 1 port shown on the diagram below.
COM 1
4. Switch on the controller.
5. Follow the instructions in the Engineering Software Manual with regard to first time
configuration.
6. Some functions of the software are only accessible by the factory and will not be
active. These are:
Variable names
Step types
Pressure lookup table
Error names

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HIGH TEMPERATURE STEAM STERILIZER

 ENGINEERING SOFTWARE MANUAL

HIGH TEMPERATURE STEAM STERILIZER

This manual includes autoclaves fitted with integral steam generators.

1. Preventative Maintenance Servicing ................................................ 3

The autoclave is to be maintained in good working order by regular servicing of the

1.1 User maintenance

 Check that the strainer over the chamber exhaust is clear.

 Check that there is sufficient printer paper for the day.

 While the chamber is cold, the autoclave is switched off,

 While the chamber is hot:

 Check the autoclave for any leaks and tighten fittings

 Run a vacuum leak test.

 Check all electrical connections for tightness, especially the

Once the servicing is complete, switch on the autoclave:

Once the servicing is complete, switch on the autoclave:

Statutory inspections Periodic safety inspections or tests such as electrical

2.1 Error messages.

ERROR MESSAGE CAUSE OF ERROR

Jacket temperature sensor is faulty.

Steam to jacket valve is not shutting off

Steam to jacket valve is not being de-

Boiler or mains steam pressure is low.

Jacket temperature sensor is faulty or the

Steam to jacket valve is not opening when

Steam to jacket valve is not being energised

Water tank temperature sensor is faulty.

Failure of the water supply.

Water valve does not open when energised.

Water valve is not energised due to faulty

Water valve relay is not energised due to

Water tank temperature sensor is faulty.

Water supply temperature is too low.

Power failure This error will be visible on the display if a

Power supply failure to the autoclave.

Control circuit breaker has tripped.

Emergency stop button has been pressed.

Chamber temperature probe fault

Bleed orifice blocked

Chamber strainer blocked

Boiler or mains steam pressure low

Bleed valve does not open when energised

Bleed valve not being energised due to faulty

Chamber temperature probe fault

Chamber pressure probe fault

Boiler or mains steam pressure too high

Jacket temperature sensor faulty

Jacket steam traps are not removing

Steam to jacket valve is not shutting off

Steam to jacket valve is not being de-

Jacket temperature error Jacket temperature is out of range

Faulty jacket temperature sensor

Faulty analogue input module.

Faulty water tank temperature sensor

Faulty analogue input module.

Faulty chamber temperature sensor

Faulty analogue input module.

Faulty chamber temperature sensor

Faulty analogue input module.

Faulty chamber pressure sensor

Faulty pressure input module.

Dirty door jammed by gasket or other object.

Dirty door motor faulty