ASC Equipment Testing Manual

Controls Engineering
Standards
Equipment Testing Manual
Document #: 62590, Revision: ORG

Copyright © 2014, ASC Process Systems, Inc
Document #: 62590 Effective Date: 9/6/14 Revision: ORG
Table of Contents
Chapter 1 - Introduction ......................................................................... 11

Chapter 2 - Expectations ........................................................................ 12
General ...................................................................................................................... 12
Testing Time ............................................................................................................. 12
What do I need for testing? ..................................................................................... 12
Safety Requirements................................................................................................ 12
Common mistakes to avoid during testing. ........................................................... 12
What to do during Equipment NCRs/ changes while testing. .............................. 12
Chapter 3 - Process Flow ....................................................................... 14

Instructions ............................................................................................................... 14
Chapter 4 - Pre-Testing Forms and Test Plan ....................................... 15

Spec Review Validation Form (62686) .................................................................... 15
Electrical Utilities Request Form (64026) ............................................................... 15
Mechanical Utilities Request Form (64560) ............................................................ 15
Test Plan (66177) ...................................................................................................... 15
Autoclave Testing .................................................................................................... 15
Specification Review ................................................................................................ 15
Test Plan Document ................................................................................................. 16
Initial Startup ............................................................................................................ 16
Test Runs .................................................................................................................. 17
Spec Review Approval ............................................................................................. 18
CPC Configuration Authorization Form (65274) .................................................... 18
Equipment Testing Authorization Form (65275) .................................................... 18
Chapter 5 - P&I Check ............................................................................ 19

What is a P&I Check ................................................................................................. 19
P&I Drawings ............................................................................................................ 19

Identify Systems ....................................................................................................... 19
Choose a System ..................................................................................................... 19
Begin Inspection ...................................................................................................... 20
Identify Errors ........................................................................................................... 20
Things to Check For................................................................................................. 21
Non Conformance Report (NCR)............................................................................. 21
Report Findings ........................................................................................................ 22
Example of Report Findings:................................................................................... 22
Chapter 6 - Creation of the I/O List ........................................................ 23

Creating the I/O List ................................................................................................. 23
What is this document? ........................................................................................... 23
Procedure ................................................................................................................. 23
Review the Drawings ............................................................................................... 24
Begin Filling the I/O list Generator ......................................................................... 24
Adding Modules ....................................................................................................... 24
Add Information to I/O List ...................................................................................... 26
Creating I/O List and Tags for Allen Bradley Program .......................................... 29
Chapter 7 - Procedure for Allen Bradley Programming ....................... 30

Introduction – How Data is Organized in the PLC Program ................................. 30
Setting up RSLogix 5000 ......................................................................................... 31
Adding I/O Modules.................................................................................................. 31
Configuring I/O Modules .......................................................................................... 32
Configure Digital Output Modules .......................................................................... 33
Configure Analog Input Modules ............................................................................ 33
Configure Analog Output Modules ......................................................................... 35
Configure Data Types .............................................................................................. 37
I/O Module Data Types ............................................................................................. 37
Buffer Rack Data Types ........................................................................................... 38

Create Tags ............................................................................................................... 39
If You Have Used the IO List Tag Generator: ......................................................... 40
If You Need to Create Tags Manually: .................................................................... 40
Create PLC Program (Ladder Logic) ...................................................................... 41
Main Routine ............................................................................................................. 42
Buffer Inputs ............................................................................................................. 43
Buffer Outputs .......................................................................................................... 43
PC Inputs .................................................................................................................. 44
Alarm Logic .............................................................................................................. 44
PC Fail Logic............................................................................................................. 46
Main Logic ................................................................................................................ 47
Virtual Inputs (Digital outputs used as digital inputs to PC) ................................ 54
Bridge Logic ............................................................................................................. 54
Door ........................................................................................................................... 54
Oxygen Analyzer Logic............................................................................................ 54
Chapter 8 - Software Simulation ............................................................ 55

Description ............................................................................................................... 55
PLC Checklist Items............................................................................................................................. 55
CPC Checklist Items ............................................................................................................................ 58
Chapter 9 Flashing the PLC ................................................................... 64

Flashing processor using CF Memory card ........................................................... 64
What is this document?........................................................................................................................ 64
What you will need: .............................................................................................................................. 64
Flash Processor ................................................................................................................................... 64
Run Program ........................................................................................................................................ 66
Flash new firmware to the processor using RSLogix ........................................... 66

Check PLC after Flashing: ....................................................................................... 67
Check Processor.................................................................................................................................. 67
Copying an Existing CompactFlash Memory ........................................................ 70

Memory card requirements: ................................................................................................................. 70
How the PLC Uses a CF Card: ............................................................................................................ 70
Changing a PLC’s installed program using a memory card: ............................................................... 70
Storing a new PLC project to a memory card: ..................................................................................... 70
How to duplicate a memory card: ........................................................................................................ 71
Chapter 10 VFD Setup ............................................................................ 73

VFD Setup manual............................................................................................................................... 73
Before Power-up .................................................................................................................................. 73
Setting Parameters .............................................................................................................................. 73
Parameters .......................................................................................................................................... 73
Summary of Standard Settings ............................................................................................................ 74
Chapter 11 Panel Test IN13 .................................................................... 75

IN13 and IO List ................................................................................................................................... 75
Electrical Drawings .............................................................................................................................. 75
Electrical Inspection ............................................................................................................................. 75
Identify Errors ....................................................................................................................................... 75
Things to Check For:............................................................................................................................ 75
Non Conformance Report (NCR)......................................................................................................... 75
PLC Program ....................................................................................................................................... 76
Setting your PC’s Ethernet Controller (LAN Connection) to Static IP Address ................................... 77
Setting IP address on new PLC processor (using BOOTP) ................................................................ 77
Forcing I/O through Local Tags ........................................................................................................... 78
Forcing Digital Modules (ON-OFF modules) ....................................................................................... 80
Forcing Analog Modules (0-100%) ...................................................................................................... 81
Output Testing ..................................................................................................................................... 81
Input Testing ........................................................................................................................................ 82
Thermocouple Testing ......................................................................................................................... 82
Finishing I/O testing ............................................................................................................................. 82
Programming the High Limit Controller................................................................................................ 82
Select Mode ......................................................................................................................................... 82
Configure Thermocouple Type and Scale ........................................................................................... 83

Set Limit Temperature ......................................................................................................................... 83
Return to Operator Mode (Main Screen) ............................................................................................. 83
Watlow EZ-Zone Limit Controller ......................................................................................................... 83
Clean-up .............................................................................................................................................. 84
Chapter 12 Cooling Check ..................................................................... 85

Autoclave Cooling Check ........................................................................................ 85
Visual Pre-Check ................................................................................................................................. 85
Fill the Cooling Tank (if applicable) ...................................................................................................... 85
Before You Begin ................................................................................................................................. 85
Begin Cooling ........................................................................................................... 86

Inspection ................................................................................................................. 86
Immediate Piping Inspection ................................................................................................................ 86
Full Piping Inspection ........................................................................................................................... 86
Important inspection points .................................................................................................................. 86
Check Ball Valves ................................................................................................................................ 88
Continue Running ................................................................................................................................ 88
Chapter 13 Heater Check ....................................................................... 89

Autoclave Heater Check .......................................................................................... 89
Insulation Resistance Testing with SCR ................................................................ 89
General Layout .................................................................................................................................... 89
Insulation Megohm Testing .................................................................................................................. 90
Element Resistance testing ..................................................................................... 92

Test 1 ................................................................................................................................................... 92
Test 2 ................................................................................................................................................... 94
Begin Testing ....................................................................................................................................... 94
Chapter 14 Fan Check ............................................................................ 95

Fan Direction ............................................................................................................ 95
If the fins lean to the right .................................................................................................................... 95
If the fins lean to the left ....................................................................................................................... 95
Airflow ....................................................................................................................... 95

Chapter 15 Calibration & Certification .................................................. 96
Calibration Equipment ............................................................................................. 96
Metrology standards (Pressure/Vacuum, Thermocouple) ................................................................... 96
Pressure/vacuum hand pump .............................................................................................................. 96
Poly tubing with fittings ........................................................................................................................ 96
Thermocouple jumper wires (Type J, Type K) ..................................................................................... 96
Getting Calibration Equipment................................................................................ 97

Calibration ................................................................................................................ 97
Pressure Calibration ............................................................................................................................ 97
Vacuum Calibration.............................................................................................................................. 98
Thermocouple Calibration .................................................................................................................. 100
Certification ............................................................................................................ 102

Pressure and Vacuum Certification ................................................................................................... 102
Thermocouple Certification ................................................................................................................ 103
Overpressure Switch Calibration .......................................................................... 104

Equipment Certification Documentation .............................................................. 104
Troubleshooting Calibration Issues ..................................................................... 105
Chapter 16 Vacuum Leak Check .......................................................... 106

Procedure ............................................................................................................... 106
Connect Vacuum Lines ...................................................................................................................... 106
Verify Calibration................................................................................................................................ 106
Check Vacuum Source Lines ............................................................................................................ 106
Run Initial CPC Leak Check .............................................................................................................. 107
Final Leak Check ............................................................................................................................... 108
Required Documentation ....................................................................................... 108
Chapter 17 Pressure Leak Test ............................................................ 109

Initial Walk Through ............................................................................................... 109
Description ......................................................................................................................................... 109
Procedure .......................................................................................................................................... 109
Initial Pressurization .............................................................................................. 113

Description ......................................................................................................................................... 113
Procedure .......................................................................................................................................... 113
Pressure Leak Test and Certification ................................................................... 116

Description ......................................................................................................................................... 116
Procedure .......................................................................................................................................... 116
Chapter 18 PID ...................................................................................... 119

PID Tuning in CPC.................................................................................................. 119
What is PID? ...................................................................................................................................... 119
PID terms ........................................................................................................................................... 119
PID terms used by CPC ..................................................................................................................... 120
CPC properties use for PID ............................................................................................................... 120
Op defined ......................................................................................................................................... 120
Oi defined ........................................................................................................................................... 120
Od defined ......................................................................................................................................... 120
CPC’s Output_PID Object ...................................................................................... 121

Attachment ......................................................................................................................................... 121
ControlMode ...................................................................................................................................... 121
AutoSetpoint ...................................................................................................................................... 122
MainSetpoint ...................................................................................................................................... 122
OutputValue ....................................................................................................................................... 122
PropBand ........................................................................................................................................... 122
Reset .................................................................................................................................................. 122
Rate.................................................................................................................................................... 122
BandOffset ......................................................................................................................................... 122
LastTime ............................................................................................................................................ 123
LastError ............................................................................................................................................ 123
Integral ............................................................................................................................................... 123
Do_Calc ............................................................................................................................................. 123
Do_Send ............................................................................................................................................ 123
Do_Send ............................................................................................................................................ 123
ForcedValue ....................................................................................................................................... 123

MaxSetpoint ....................................................................................................................................... 123
MinSetpoint ........................................................................................................................................ 123
MaxOutput ......................................................................................................................................... 124
MinOutput .......................................................................................................................................... 124
VariableMaxSetpoint .......................................................................................................................... 124
MaxIntegral ........................................................................................................................................ 124
MinIntegral ......................................................................................................................................... 124
MinIntegral ......................................................................................................................................... 124
TaskerForCalc ................................................................................................................................... 124
TaskerForSend .................................................................................................................................. 124
AutoSetpointSourcePath ................................................................................................................... 124
Chapter 19 CPC – IntegralScrubbing Object ...................................... 125

Purpose of integral scrubbing .............................................................................. 125
IntegralScrubbing Object ...................................................................................... 126
Scrub Table editing ............................................................................................................................ 127
Add IntegralScrubbing to main tasker................................................................................................ 128
Chapter 20 Post-Testing documentation and forms .......................... 129

Shop Test Completion Form ................................................................................. 129
Final Meets Inspection ........................................................................................... 131
In House ............................................................................................................................................. 131
On – Site ............................................................................................................................................ 133

Chapter 1 - Introduction
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Chapter 1 - Introduction
This manual features detailed standards on how to test equipment built by ASC Process Systems.
In order to perform testing, you will need a general set of tools, such as screwdrivers, wrenches,
lubricants, and cleaning materials, among others. Some items will require calibration and the expertise of
a qualified N.I.S.T. electrician.
If you have any questions regarding the applicability of a specific section of this manual, refer to the
engineering drawings, process and instrumentation diagrams, cut-sheets, brochures, etc. that are
provided with this manual.
This manual is not intended to be a substitute for knowledge of common industrial maintenance practices,
common sense, and the supporting manuals, cut-sheets, and brochures supplied with this system. Make
sure you read and understand all of the applicable manuals before working on the equipment. Take
special notice of all safety precautions and warnings in the instruction manuals.
Furthermore, pay special attention to the red outline boxes in this manual. The red outline boxes
indicate safety hazards that require your attention.

Chapter 2 - Expectations
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General
This applies to jobs both in the shop and the field. All the required forms for testing can be found in OMS.
Please do not keep local copies of the forms as these form will be updated periodically. Take the latest form
OMS prior to starting the job. You can email of copy of the form to the authorized approvers for email approval
if in the field.
Testing Time
When testing equipment, be in the shop at 7:00 am. This is to make sure controls engineers are on same
schedule as the shop, and prevent overtime for electricians and mechanics if testing takes longer than
expected. Weekend work might be required but this has to be approved by manager prior to the weekend.
What do I need for testing?

Signed copy of Form # 65275
CPC must be fully configured and simulated before beginning shop testing.
Personal tools
Testing cart – labeled “Controls Engineering”
Laptop
Equipment PC(s)
Calibration kit (as required)
Safety Requirements
Testing should utilize all regulated PPE.
• Refer to ASC’s NFPA 70E standard practices.
ASC electricians qualified to ASC procedures.
Use proper signage and guarding for powered conditions.
Insure that proper PPE is utilized (depends on voltage).
Maintain and supervise 70E limited and restricted boundaries.
Utilize proper NFPA 70E PPE for power-up of all voltages 50V and over.
Common mistakes to avoid during testing.

Check all vessel penetrations to make sure they are plugged and tightened before testing with
pressure.
Test drain tank level sensors before running any cooling. This is to prevent overflow of cooling water.
What to do during Equipment NCRs/ changes while testing.

For short NCRs or repairs, do not leave the equipment or go back to the office to work on other jobs. This is to
make sure the equipment is fixed quickly during the testing period, and so workers do not go on to other work
before fixing the problem.

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For long NCRs (e.g. many hours or days), this may not apply. Manager will reassign controls engineers to
other jobs.

Chapter 3 – Process Flow
Page 14 of 136
Chapter 3 - Process Flow

Instructions
When working on any equipment, be sure to always be aware of your surroundings. Pay special attention to
hazardous situations, and be sure to follow the tips outlined in the safety notes. The safety notes can be easily
identified in the manual by finding any note with a red outline box .

Chapter 4 – Pre-Testing Forms and Test Plan
Page 15 of 136
Chapter 4 - Pre-Testing Forms and Test Plan

Spec Review Validation Form (62686)
This form is to ensure the engineer has looked at the specification and is familiar with the requirements of this
job. With the approval of this form comes the approval of the test plan and the mechanical and electrical
utilities request, so be sure these forms accompany the spec review.
Electrical Utilities Request Form (64026)

This form notifies the Electrical Fabrication Manager what utilities will be needed, and when. This also gets
posted at the autoclave so the Electrician knows what is needed for testing. All information can be found on the
electrical drawings. Generators are usually only used for international projects with different voltage
requirements.
Mechanical Utilities Request Form (64560)

This form notifies the Mechanical Fabrication Manager what utilities will be needed, and when. This also gets
posted at the autoclave so the Mechanical Fabricator knows what is needed for testing. Most of the information
can be found on the P&I drawings and spec.
Be sure to indicate on the form what pressure is required for the inlet, or else you may just get shop air that
only goes to about 110PSI.
Nitrogen is required if the temperature is greater than 500F. Sometimes nitrogen is used in testing to get a
greater inlet pressure than the shop source.
If load is specified for testing, it needs to be approved and included on this form. The shop only has the
capability to test up to 8,000lbs. If the load required is greater, it will have to be tested with just 8,000lbs.
If the autoclave is fairly short, it needs 90s on the exhaust and relief valve to avoid injuring any nearby
personnel.
Test Plan (66177)
Autoclave Testing
Testing an autoclave before it ships to site is very important. There are many tests that need to be run, and
each autoclave will need something different. Creating a test plan ensures that things will not be forgotten.
Specification Review
Before creating a test plan, you will need to know some information about the autoclave. What units will it be
in? What are the heating/pressurization rates that need to be met? Are there any CIR runs that should be
tested? Print out the specification from OMS and go over it, highlighting the important parts. If the customer
has filled out a CIR, print that out as well.

Page 16 of 136
Test Plan Document

Test plans should be updated daily with any changes or progress and reported back with your daily
update.
If a task on the test plan is done you should update the plan by writing done under the task. The test
plan should be included in the daily report and you should be sent to the Electrical Engineering
Manager and cc’d to, Project manager, Mechanical Fabrication Manager, Electrical Fabrication
Manager, Planning manager, Quality manager, Project Electrical Engineer, and President so that
everyone is on the same page. Highlight any days outside the originally planned completion date in
red. Highlight days that were completed per plan in Green and highlight days that are partially
completed but has some tasks go in to a different day in Yellow. Please see example of test plan
below:
7:00
Date AM 9:00 AM 11:00 AM 1:00 PM 3:00 PM
Thursday
5/28 Vacuum Leak Check DONE
Friday
5/29 Vacuum Leak Check DONE
Monday Heater
6/1 Check IN11 Tuning Run
Tuesday
6/2 Tuning/ temp control run
Wednesday
6/3 Test Run 1: Uniformity
Thursday Test Run 2: Max

6/4 temp/rate Complete outstanding tasks
Thursday Test Run 2: Max

6/5 temp/rate rerun
Initial Startup
There are a couple things that need to get done before full tests can be run. Be sure time for these is included
in the test plan.
1. I/O Bump:
a. All of the IO needs to be checked from both the PLC and CPC to make sure it is wired
properly and is working.
2. IN11 Document:
a. The IN11 document that covers safety interlocks should be filled out at this time. It can be
found on OMS.
3. Fan Check:

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a. The fan needs to run in the correct direction, quietly, and with the proper airflow.
b. Check the engineer’s fan calculation sheet for airspeed under the floor, and measure with an
anemometer.
4. Heater Check:
a. Heater needs to be checked for shorts, and that the scr/ssr is behaving properly.
5. Cooling Check:
a. Cooling system needs to be checked for leaks, and proper behavior of cooling valves.
6. Sensor Calibration/Certification:
a. All of the TC’s need calibration, and the PTCs/AirTC need certification. All of the Vacuum
probes and SVAC need calibration/certification.
7. Vacuum Leak Check:
a. The vacuum system needs to be tested for leaks.
8. Pressure Leak Check:
a. The autoclave needs to be pressurized to check for leaks.
b. All holes need to be plugged, and all pass-throughs tightened fully. Capsule needs to be
properly tightened.
Test Runs
There are multiple tests that need to be run. Many of these can be combined into a single run.
1. Pressure Control:
a. Demonstrate pressure control by ramping up to a few different pressures and back down at
various rates. Hold at each point for stability.
2. Temperature Control:
a. Demonstrate temperature control by ramping up to a few different temperatures and back

down. Use different rates at each step, and make sure the temperature meets the ramp. Make
sure tuning is solid. Hold at each step for stability.
3. Vacuum Control and Capability:
a. Demonstrate vacuum control and capability by pulling vacuum down to maximum (should be
around -28.5/-29 InHg for Valencia) in steps. Should be within 1 InHg to setpoint.
4. Pressure Rate:
a. Pressurize to instantaneous max pressure (by setting rate in the recipe to X). Measure the
average rate to Max pressure. Should match or beat the Max pressure rate in spec.
5. Pressure Capability:
a. Pressurize to max pressure. Should hold at maximum without problems. Hold for stability.
6. Temperature Rate:

Page 18 of 136
a. Heat to max temperature at an instantaneous rate (rate set to X). Measure the average heat
rate to max temperature. Should match or beat the Heat rate in Spec.
7. Temperature Capability:
a. Heat to Max temp and hold for stability. Usually done with load, if required. Temperature
should hold at maximum without issues.
8. Temperature Uniformity:
a. Uniformity test is to be done unloaded at 45psi. With 9 PTCs per 10,000 cu ft, Heat to 3
different temperatures, plus max working temperature. Hold each for 40 minutes for stability.
The PTCs should be +/- 10deg from AirTC. HilimitTC should be less than 50Deg above AirTC.
9. CIR:
a. If the customer has specified the most used runs in the CIR, these can be added to the test
plan.
Spec Review Approval

After you have a test plan, it needs to be approved. Most likely, the testing dates will get moved around,
depending on when the autoclave is finished and ready for testing. The Test Plan will be submitted for
approval with the Spec Review Validation Form (62686). Also needed with this form are the Electrical and
Mechanical utilities forms (64026, 64560). Once these forms are signed by the appropriate people, they need
to be scanned by document control and put in the job folder on the server.
CPC Configuration Authorization Form (65274)

Before the CPC Objects file can be made, the CPC CAF form needs to be filled out and approved. This form
ensures that CPC is configured correctly, according to the customer’s request. This will be confirmed with both
the CIR/spec and the actual customer through phone or email. Also, the object file that this project will be
based upon needs to be included in the CAF. It should have the same systems, but not necessarily the same
size or temp/press.
Equipment Testing Authorization Form (65275)

Once all these forms are completed and on the server, the Equipment Testing Authorization Form (65275) can
be filled out and signed. You will also need to complete the I/O list, PLC program, and CPC Objects file. You
will need this completed form for the Hazard Analysis approval by the Safety Department.

Chapter 5 – P&I Check
Page 19 of 136
Chapter 5 - P&I Check

What is a P&I Check
A P&I check is a visual/physical inspection that all of the Piping & Instrumentation (P&I) correctly match what is
described in the P&I drawings.
P&I Drawings
In order to conduct a P&I Check you will need the most up to date P&I Drawings for the project. In many cases
there are several revisions of these drawings and if yours is not up to date, that can lead to errors when
conducting the inspection. Request the drawings from Document Control and inform them it is for ‘Inspection
Only’.
Identify Systems
The P&I Interconnect page is a block diagram with all of the different systems on the autoclave and how they
are interconnected. Each block will indicate the system name and a drawing number. Make sure you have a
drawing for each system.
Choose a System
You will begin by choosing a page and identifying the system it belongs to. It is described in the bottom right
corner of the page.

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System Name
Drawing Number
Begin Inspection
Once you have physically identified the section you will be working with on the autoclave, match every pipe
and instrument to the drawing. Once a pipe/instrument has been correctly matched, highlight it on the page
with a yellow or green highlighter. Do NOT mark the pipe/instrument if the work is not correct. Once the page is
complete, go back to the interconnect page and highlight the system indicating it is complete.
Identify Errors
If an error or mismatch from the work to the drawings is found, circle it and write down a quick description of
the error. Once the page is completed, Sign and date/time the page.

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Things to Check For

Correct Instrument (Ball/gate/globe/pneumatic/electric valve, etc.)
Correct instrument specs (specs on nameplate/sticker must match BOM)
• Voltage
• Horsepower
• Direction of flow
Correct pipe size
NO open vessel penetrations. Must be used or plugged.
Non Conformance Report (NCR)

For any changes or fixes to be addressed, a NCR form must be issued. Before that you must fill out a Pre-
NCR form (#38405) and record all of your findings there. Once completed, deliver this form to the Mechanical
Fabrication and Assembly Manager.

Page 22 of 136
Report Findings
The report should be sent to the Project manager and cc’d to Electrical Engineering Manager, Mechanical
Fabrication Manager, Electrical Fabrication Manager, Planning manager, Quality manager, Project Electrical
Engineer, and President so that everyone is on the same page. If items remain to be finished, the project
manager will coordinate with production and champion the remaining items. Project manager is responsible to
follow up on the items and report back to Testing engineer and electrical engineering manager with the
progress and estimates on completions. Project manager shall update the report every day, attach it to the
update email, and add it to the job folder on the server. The email will update all affected parties on current
issues and fixes whereas the document will be the history of issues that occurred. Note: It’s always a good
idea to include pictures.
In the email include the finding/s and what has been done to correct it (eg: NCR issued, mechanic corrected
etc.).
Example of Report Findings:

UTCAS – 13267 P&I Check Findings (2/24/2014)
Drain Down System DWG# 38283

MTR3500: Drain tank motor is listed as 3/4HP in the BOM but the actual one is 1/2HP
Cooling Valve System DWG# 46560

CHK3002: The check valve connected to the Trim Water line is pointing in the wrong direction. Trim water will not work until corrected.
Fan System DWG# 61919

Capsule: The fan capsule is obstructed by the water inlet line for the tower cooling system. With this obstruction I will not be able to test cooling and run the
fan motor. <PICTURE>
Vacuum Probe System DWG# 50082

Internal Calibration Source: The Vacuum probes are connected in such a way to allow single or joint calibration through an internal source (included vacuum
system) or through an external source (eg: calibration pump). The line for ‘internal’ calibration is connected in the wrong location (red circle). The internal
vacuum source will constantly be vented through the 5th valve from the left if not corrected. It should be connected to the 5th valve (green circle). <PICTURE>
Vacuum Source System DWG# 40789

HOV2110: This is the isolation valve from the vacuum lines and the receiver tank.
HOV2111+Pressure Connection Point: There is no way to connect a pressure line two the vacuum lines which is used for trouble shooting in the event of a
vacuum leak. <PICTURE>

Chapter 6 – Creation of the I/O List
Page 23 of 136
Chapter 6 - Creation of the I/O List

Creating the I/O List
What is this document?

This document explains and defines a standard and procedure on how to create and use a functional I/O list.
Before creating the I/O list all resources must be collected and organized.
Procedure
1. Go to document control and ask for a “For Inspection” copy of the electrical drawings for your job.
a. Once your drawings are ready, pick them up in document control.
2. In OMS get a copy of the most recent I/O list generator ASCItem# 62600
a. In OMS go to Parts and Items
b. Type in ASCItem# 62600 in the ASCItem field and hit enter.
c. Click on the only item present in the part/item list, titled “FORM, CONTROLS ENGINEERING,
I/O LIST TEMPLATE.”
d. Click on the folder field with the numbers 62600 in it
i. A hand will appear when the cursor is placed over the field.
e. A window will open up linking you to the folder where the Excel document is stored.
f. Copy and paste the Excel document to your hard drive.

Page 24 of 136
Review the Drawings

1. Go through each page received and ensure that no page is missing.
a. The Page numbers are located at the bottom right hand corner in the title block.
2. Study the Control Wiring drawings to ensure you understand what is trying to be accomplished.
a. See what modules are being used
b. The rack number
c. The slot number of each module
i. The module info will be located at the top of the module, as shown below.
Begin Filling the I/O list Generator

1. Open the Excel 62600 IO List Generator document.
a. Enable any macros that may be disabled.
2. Go to the first sheet titled “0) Instructions”
3. Read through the instructions, understand them and follow them.
Adding Modules
1. Go to the second sheet of the I/O generator document labeled, “1) IO List Generator”

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2. Click the “Clear IO List” button to delete an existing IO List from the generator
a. Always start with a clear IO list generator
3. Copy and paste the correct PLC modules in order of Rack and Slot number from the right hand side of
the sheet to the left side under the section titled “Add module info to this list:”
a. Always start with the list with the Processor (Slot 0).
b. Fill in the appropriate Rack Number and Slot Number to each module
c. You can find the processor information in the Rack layout located in the Controls Wiring
drawings.

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4. Once completed click on the “Generate IO List” button
Add Information to I/O List

1. Go to the third sheet of the I/O generator document labeled, “2) IO List”
2. On the top left corner of the sheet enter the Job#, Customer, and Model# of the Econoclave.
3. Using the names used for every channel of the I/O modules from the Controls Wiring drawings name
each channel on the IO List Under the column description.
a. Reference document “IO Naming Convention Standard 2014-06-16” for the ASC’s tag
naming convention and abbreviation standards.
i. File Path: Z:\ASC Engineering\3 - Controls Engineering\6 - Unapproved

docs\Procedures\Design manual\Scott
4. Fill in the wire# of each channel referencing the Control Wiring drawings for appropriate wire numbers.
5. Fill in appropriate CPC Index and Bit values
a. The Index refers to the WORD of data, 16 bits, in the series within the I/O category.
b. There are four categories of I/Os:
i. Digital Input Modules
ii. Digital Output Modules
iii. Analog Input Modules
iv. Analog Output Modules

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c. Each category’s first WORD begins with an Index of 0 and builds up incrementally.
HOWEVER, Leave digital I/O index 0 for internal use only, such as the pulse. Start these at
index 1 if there are no internal I/O. Analog I/O will start at 0.
i. Each Analog Input and Analog Output is a Real Number data type which is the length
of a WORD, thus each Analog Input and Analog Output gets assigned an individual
Index value.
1. Analog Inputs and Analog Outputs do not receive a bit assignment.
d. Only Digital Inputs and Digital Outputs are assigned bits.
i. Digital Inputs and Digital Outputs are Bool data types which are only the length of a bit
(True or False).

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ii. If the Digital Input or Digital Output module only contains 8 channels, uses only 8 bits,
that module gets assigned its own unique Index. Any subsequent modules get
assigned an incremental value Index.

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e. When using the I/O generator, the bit values get automatically assigned. Only the Indexes
must be entered.
Creating I/O List and Tags for Allen Bradley Program

1. Go to the fourth sheet of the I/O generator document labeled, “3) Tag Generator”
2. Read the instructions and click the “Generate All Tags” button.
a. If button does not show up, zoom in or out of the page to make the button reappear.
b. The I/O List titled “IO List (Job#)” and “Tags_(Job#)” will automatically be saved to your
desktop.

Chapter 7 – Procedure for Allen Bradley Programming
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Chapter 7 - Procedure for Allen Bradley Programming

This procedure is for programming a PLC using RSLogix 5000 after the PLC processor has been installed in
the panel and the IO list has been created using the I/O list portion of this document.
Introduction – How Data is Organized in the PLC Program

The PLC program will perform calculations and logic to transfer between different sets of data. Three sets of
data are used to represent inputs and outputs:
“Local” data, which is the status of physical locations on the PLC modules.
“Buffer Rack”, which stores the information after it goes through PLC logic.
“PC” data, used to store outputs from CPC.
The following diagram shows how data is moved through the program using subroutines.
PC data Local
Buffer (physical
(to/from Rack PLC
CPC) status)
“PC Inputs” ”Buffer Inputs”
DI DI DI
← copy ← ← copy ←
“Main Logic” “Buffer Outputs”
DO DO DO
→ logic / OTE outputs → → copy →
“PC Inputs” “Buffer Inputs”
AI AI AI
← copy ← ← compute ← move to temp ←
“Main Logic” “Buffer Outputs”
AO AO AO
→ logic / move → → compute →

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Setting up RSLogix 5000

1. Open RSLogix 5000 and start a new project.
2. Select the main processor from the list. Check the control wiring schematic for the correct processor.
Check the name on the front of the physical PLC processor module. In most cases, the main
processor will be either 1769-L32E or 1769-L35E. Select the revision. Type a name for the project,
then click OK.
Adding I/O Modules

Add the modules that this processor will monitor/control. The electrical drawings will show the modules that are
required for the project. This information should also be on your IO List. The modules will consist of digital
inputs/outputs cards, and analog inputs/outputs cards. The following steps explain the basic setup of each IO
module.
1. Find “CompactBus Local” in the tree. Right click, select “New Module”
2. Find the correct module, and then click OK.
3. Select the correct slot number, and then name the module using the naming scheme RX_SX. For
example, Rack 1, Slot 1 would be named “R1_S1”.

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4. Click “Change”, and then select the correct revision of the module (firmware revision). There are two
ways to find the correct revision:
a. If the PLC is connected in RSLinx, find the module in the tree, then right click and select
“Properties”.
b. You can also check the label on the side of the module where it says “F/W Rev”.
5. In the “Connection” tab, uncheck “Major Fault On Controller If Connection Fail While in Run Mode”
6. Click OK to save changes to the module.
7. Repeat for all modules in the IO list.
Configuring I/O Modules

Once you have inserted the modules that will be used on the program, you need to configure each module.
In order to configure a module, you can re-enter the Settings screen by double-clicking on the module.
Digital input modules do not require any further configuration.

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Configure Digital Output Modules

If the digital output modules have a “Fault/Program Action” tab, use the settings shown below. If this tab is not
shown, no further configuration is required.
Configure Analog Input Modules

Two types of analog input modules are used:
General modules (used for pressure transducers)
Thermocouple Modules (e.g. 1769sc-IT6I)
1. Configuration tab:
a. Enable: enable all.
Thermocouple modules (1769sc-IT6I) have “disable” here – leave this unchecked.
b. Input range: Set input range according to function. Look on your IO list for the range. This is
usually -10V to +10V.
c. Filter:
i. For general use modules, set filter according to main power (60 Hz for North America,
50 Hz in many other locations).
ii. For Thermocouple modules, use 4.17 Hz for both Type J and Type K. Check control
wiring schematic for thermocouple type.
d. Data Format: Use Engineering Units (Engineering Units X1 for thermocouples).

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e. Sensor Type (thermocouple modules): Usually Type J or Type K. Check control wiring
schematic.
f. Units (thermocouple modules): Can be F or C, depending on the project specifications.
g. Open Circuit Response (thermocouple modules): Upscale
h. Channel Display (thermocouple modules): select Data Value.
i. CJC Offset (thermocouple modules): leave this set to 0.

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2. Alarms tab (if shown):
a. Make sure “Disable Alarms” is checked.
b. Make sure “High”, “Low”, and “Deadband” are set to zero.
Configure Analog Output Modules

Analog outputs are used to control proportional valves, VFDs, and SCRs for heating. They use a 4 – 20 mA
signal.
1. Configuration tab:
a. Enable: select all.
b. Output range: look at your IO list. Usually 4mA to 20mA.
c. Data Format: select “Engineering Units”

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2. Limits tab: set the limits for each channel. For 4-20 mA, the units will be in µA. E.g. 4 mA = 4000 µA.
3. If there is a “Fault/Program Action” tab, enter the following values as shown below.

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Configure Data Types

We want to be able to address a single input or output as a hierarchy of rack.slot.channel, e.g.
“Rack1.Slot1.Ch0”. To do this, we must create a user-defined data type to represent each size analog IO
card, and another user-defined data type to represent the entire rack.
Note that discrete IO cards do not need a user-defined data type, since they can be represented by a single
INT (16 bit), where each bit can be addressed individually).
I/O Module Data Types

1. Create a data type for each analog module size (e.g. 4ch, 6ch, 8ch).
a. Expand the tree for “Data Types”
b. Right click on “User-Defined”
c. Click “New Data Type”.
d. Add the correct number of channels corresponding to the number of inputs/outputs on the
module
e. Select “REAL” for the data type of each channel.

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The example below shows a data type that contains 4 channels with real/floating point values (32-bit).
Buffer Rack Data Types

1. Create a data type for each buffer rack. Name each rack “BUF_RACK_#” or “BUF_RACK” if only one
rack/PLC is being used.
2. Add a member for each slot. Look at your IO list to figure out what is needed for each slot.
3. Pick a data type for each slot.

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a. Discrete input/output modules can be represented using INT (16 bits).
b. For analog modules, use the data types you created in step 1 above.
Create Tags
In RSLogix 5000, data is stored in locations called Tags. Tags can either be actual memory locations, or just
aliases for other tags.
The following steps show how to create the base tags for PC and Buffer Rack data (Local tags show up
automatically after configuring the IO modules). Alias tags can then be created for the newly added PC and
Buffer Rack data tags.
1. First create a single tag for each Buffer Rack
a. At the top of the tree, double click on “Controller Tags.”
b. Click on the “Edit Tags” tab on the bottom.
c. Scroll to the bottom of the list and add a new tag by typing in the blank box.
d. Create a tag for each rack. Name the first rack “Rack1.”
e. For Data Type, use “BUF_RACK” or whatever data type you created for that rack.
f. Hit enter. Now you can expand the tag and see that the structure of the tag follows the
hierarchy that you created with the “BUF_RACK” data type.
2. Create 4 tags for PC input and output: “DigInputs”, “DigOutputs”, “AnInputs”, and “AnOutputs”.
a. Double click inside the Data Type column to open up the dialog box. Select “INT” for digital, and
“REAL” for analog.

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b. Create an array for each category (AI,AO,DI,DO):
Look on your IO sheet for the “index” of each of these 4 categories. Each array needs to be
dimensioned to hold all of the values in the category. E.g. if the index for analog inputs goes from
0 to 29 (in this case over the span of 5 analog input modules), you need an array of 30 real
numbers. Type the number in “Dim 0”. Click OK.
Note that if any I/O category has more than 120 values, you will need to create multiple arrays for
that I/O category. E.g. if there are 130 analog inputs, you will need 2 arrays: AnInputs1[120] and
PCAnInputs2[10].
If You Have Used the IO List Tag Generator:

1. Import the CSV file by going to Tools > Import > Tags and Logic Comments
a. All tags should now be filled out. If there are any errors, you may be missing some buffer rack
data, as it cannot see the structure that it is being pointed to.
If You Need to Create Tags Manually:

1. Create a tag for of all items on your IO list. These will be aliases for the sub-tags within the Buffer
Rack tag.
a. Name each item on your IO list, following the naming scheme “[Type]_[Description]”. For
example, “DI_Silence”

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b. In the “Alias for” column, select the Rack, Slot, and Point corresponding to the IO sheet. For
example, “DI_Silence” is an alias for “Rack1.Slot1.0”.
c. Press enter. The rest of the information for the tag will fill in automatically.
d. Repeat for all items on the IO list.
2. Create alias tags for all PC output data.
a. Name each item “PC[Type]_[Description]”, e.g. “PCDO_TrimAir”.
b. In the “Alias for” column, select the “AnOutput”, or “DigOutput” array index corresponding to
that on your IO List.
Create PLC Program (Ladder Logic)

1. Go in the Main Program Folder. Add the following new Rountines by right clicking the folder, then
clicking “New Routine.”
a. Buffer Inputs
b. Buffer Outputs
c. PC Inputs
d. Alarm Logic
e. PC Fail Logic
f. Main logic
2. Create the following, as applicable:
a. Door
b. Bridge Logic
c. Oxygen Analyzer Logic (Use template)

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Main Routine
1. First create a “TON” timer on delay.
a. Under “Timer,” create a new timer tag. Right click on the “?” next to “Timer,” then click “new
Tag.” Name it “TmrStartup.” For the data type, select “Timer.”
b. Change the preset to 3000 (3 seconds). This is roughly the time it takes RSLogix to initialize
monitoring the inputs and determining the states of the outputs.
2. Create a rung for each of the 6 subroutines. Create a Jump to Subroutine (JSR) instruction for each
subroutine.
3. Use an Examine if Closed (XIC) instruction on each rung, as shown below. Use the “TmrStartup DN”
tag.

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Buffer Inputs
The “Buffer Inputs” routine moves values from Local (physical) to the Buffer Rack.
1. Digital Inputs: Use Synchronous Copy File (CPS). Create a block for each digital input module in your
IO list.
2. Analog Inputs: For every channel in every analog input module, create a rung with two instructions:
a. Move (MOV): moves the value from Local to a temporary location, “IntRealValue” tag. You
can create this tag by right-clicking next to “Dest”, then adding a new tag with “REAL” data
type.
b. Compute (CPT): converts the value before moving to the buffer rack.
Under “Dest”, select the alias name of the analog input from your IO sheet
Under “Expression”, use the following conversions:
i. General use modules/ vaccum probes: use expression “IntRealValue * 0.001”
This converts from mV to V.
ii. Thermocouples: use expression “IntRealValue * 0.1”
This is done because the value that is read in the PLC is 10 times the actual
temperature reading. For a temperature of 70°F you will see 700 as the value of that
input.
Buffer Outputs
The “Buffer Outputs” routine moves values from the Buffer Rack to Local (physical).
1. Digital Outputs: Use Synchronous Copy File (CPS). Create a block for each digital output module in
your IO list.

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2. Analog Outputs: Create a rung with a Compute (CPT) instruction for every channel in every analog
output module. Again, follow your IO List.
a. Under “Dest”, select the Local channel.
b. Under “Expression”, use [buffer rack alias] * 1000
This converts from mA to µA. E.g. AO_CoolingValve * 1000
PC Inputs
The “PC Inputs” routine copies values from the Buffer Rack inputs to the PC input tags.
1. Create a CPS instruction for each input module.
2. Destination is the PCDigInputs or PCAnInputs tag, starting with the array index from your IO list.
For example, PCAnInputs[0] is the first AI module with 8 inputs, and PCAnInputs[8] is the second AI
module.
3. Length:
a. For digital input modules, Length is 1.
b. For analog input modules, the length is the number of channels in the module.
Alarm Logic
All alarms coming from CPC and from Main Logic (e.g. Hi Limit, E Stop) come into this screen. All alarms
must have silence logic configured with the exception of the safety cable. The safety cable alarm must NOT
be silenced. This alarm needs to keep sounding as long as the condition exists.

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1. Hi Limit Delay:
2. Silence Bit:
The logic shown below should be repeated for all alarms, including:
a. CPC Alarm\
b. PCA Fail Alarm
c. PCB Fail Alarm
d. Hi Limit Alarm
e. E Stop Alarm
f. Safety Cable / Man Inside: The safety cable alarm must NOT be silenced. This alarm needs
to keep sounding as long as the condition exists.
3. Alarm Delay:
The following logic should be created to allow for a delay of 2 seconds before the alarm sounds:
a. Create a branch/level for each alarm included from the above instruction.
i. Each branch will include the input condition and the silence bit.
ii. The safety cable will not have a silence bit.
b. Create a TON timer with a new timer tag “TmrHornDelay” for the horn delay timer.

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4. Horn Output:
Create a rung for horn output as shown below.
PC Fail Logic
Single PC
1. Add the following tags (and data types):
a. PC_PCAPulse (BOOL)
b. TmrPulseAOn (TIMER)
c. TmrPulseAOff (TIMER)
d. int_PCAHealthy (BOOL)
2. Add the following logic:
Dual PC
For dual PC systems, reference ASC Item# 68853

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Main Logic
This is the main logic that transfers outputs from the PC to the Buffer Rack. For ALL Main Logic reference the
latest IN9 and IN11 task sheets for current ASC standard interlocks.
1. Heater:
The logic for the heater depends on what kind of device is being used to control the heater. This will
either be a discrete output controlling a solid state relay (SSR), or an analog silicon-controlled rectifier
(SCR).
a. SSR/Discrete Output
i. The first rung establishes the conditions for allowing the heater to turn on. Use the
example below and add the following instructions if needed.
1. Add instruction XIO with intPCFail to this rung if the program includes PC Fail
logic.
2. Add instruction XIC with SafetyCableOK to this rung if the autoclave includes
a safety cable.
ii. Rung 2 turns on the heater contactor. Repeat this instruction for each contactor if
there are multiple heater contactors.
iii. Rung 3 turns on the SSR. Repeat this instruction for each SSR if there are multiple
heaters.
b. SCR/Analog Output.
i. The first rung establishes the conditions for allowing the heater to turn on. Use the
example below and add the following instructions if needed.
1. Add instruction XIO with intPCFail to this rung if the program includes PC Fail
logic.
2. Add instruction XIC with SafetyCableOK to this rung if the autoclave includes
a safety cable.
ii. Rung 2 turns on the heater contactor if the heater is allowed. Repeat this instruction
for each contactor if there are multiple heater contactors.

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iii. Rung 3 moves the output value from CPC to the SCR if the heater is allowed.
iv. Rung 4 sends a 4 mA signal to the SCR if heater is not allowed.
2. Cooling
Use the following logic to control the main cooling valve:
a. The first rung moves an analog value from CPC to the buffer rack.
b. The second rung sends a 20 mA signal to the buffer rack if the High Limit turns on or if the E
Stop is pushed.
3. Main Cooling Pump:

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The cooling pump should turn on if control power is on and: if CPC requests it, if the estop is pushed,
or if the Hi Limit turns on.
4. Drain Down Valve:
If the autoclave has a drain valve, use the following interlocks, as applicable:
a. No High Limit
b. Safety Cable OK
c. No Emergency Stop
5. Drain Down Pump:
If the autoclave has a drain pump, the following conditions should turn the pump on:
a. Drain High
b. PC drain pump
c. PC Failure
6. Pressure Inlet:
a. Create a rung to turn on the Allow Pressure bit.
i. The input conditions should include the following, as applicable:
1. Door is locked
2. No High Limit
3. No PC fail

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4. No E Stop
5. Safety Cable is OK
ii. Use a new tag “Int_PressureAllow” as the output bit.
b. Create a rung to move the analog value for the pressure inlet valve from PC to buffer rack.
c. Create a rung to close the pressure inlet valve in case of the following conditions, as
applicable:
i. High Limit is triggered
ii. E Stop is pushed
iii. Door is not locked
iv. PC fail
v. Safety Cable is pulled
7. Pressure Exhaust:
a. Establish conditions for:

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8. Blower Fan:
a. Discrete output/ Digital
" MaxIntegralbe interlocked with the E Stop, as shown below.
b. VFD/Analog: Use the following:

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9. Makeup Water:
If the Autoclave has makeup water, use the following logic.
10. Stack Lights
a. Alarm Stack Light
If there is an alarm stack light, use the following logic to allow the light to blink.
b. Process Stack Light

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If there is a process stack light, the output can pass through to the buffer rack as shown
below:
11. System Vacuum & Vent:
These can pass through directly to the Buffer Rack.
a. For Digital Vac/Vent:
b. For Analog Vac/Vent:
12. The following can pass through directly to the Buffer Rack:
a. Trim Air and Trim Water:
b. Vacuum Pump on
c. Tower Fan on
d. Tower Pump on
e. Part Vacuum and Vent valves
f. Spare Slots.

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Virtual Inputs (Digital outputs used as digital inputs to PC)

Virtual Inputs are basically the digital outputs used as digital inputs. They are used in CPC for troubleshooting.
All you have to do here is create the same two blocks as you did for the Digital Input cards and use the CPC
indexes that you assigned in your IO List.
Notice that the format for “source” in block one is different as for the digital input cards.
Notice that instead of I it is now O, this is because as mentioned earlier these are digital outputs that are now
being used as inputs to CPC.
Bridge Logic
Door
Oxygen Analyzer Logic

Chapter 8 - Software Simulation
Page 55 of 136

Description
During testing, you will be filling out a checklist of parameters that must be met for each item on the I/O
list. Each check field should begin with a N indicating that the parameter has not been verified yet. As you
complete each task you will change the it to‘NA’ or ‘Y’ indicating the task has been met. ‘NA’ indicates the
task does not apply to this item. If you click on each cell in each column a drop down menu will appear
giving you an option to select a Y, N, or NA. Below is a quick description of each task along with an
illustative reference. All items covered in detail in the PLC programming portion of this document.
PLC Checklist Items

1. Panel Test
a. Has the panel been tested according to the Panel Test chapter of this document?
2. PLC Tag
a. Has a PLC tag been created as described in AB procedure guide?
i. Choice: Yes, No (All tags need to be made, including spares)

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3. PLC Logic Alarms

a. Is this Input/Output item included in the PLC Alarms Logic?
i. Choices: Yes, No, N/A
ii. Required inputs/outputs for alarm logic: NoEstop, NoHiPress, NoHiLimit,
SafetyCableOK, SilencePB, PCFail, AlarmHorn
4. PLC Main Logic

a. Is this item included in PLC Main Logic?

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i. Choices: Yes, No, N/A.

1. Required items for PLC Main Logic: Pressurization Interlocks, Heating
Interlocks, CPC Control of all outputs (contactors, motors, valves, spare
outputs).
ii.
5. PLC Fail Logic

a. Does this cause the alarm horn to activate?
ii. Required items:
1. Single PC Control: CPC Alarm, PC Fail, PCPulse
2. Dual PC Control: CPC Alarm, PCA Fail, PCB Fail, PCAPulse, PCBPulse,
PCAInCntrl, PCBInCntrl

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6. PLC Live I/O Check and Logic

a. As per the Panel Test chapter in this document, force input/outputs to activate deactivate.
Are the forced states reflected by the activation/deactivation of the controlled items? Relay?
Motor? Status light on the module?
i. Choices: Yes, No, N/A (only spares).
CPC Checklist Items

1. CPC I/O Created
a. An Input or Output has been created in CPC?
i. Choice: Yes, No, N/A (only spares)

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2. CPC Alarm Configured

a. Does the Item have an alarm message associated with it?
i. Choice: Yes, No, N/A
3. CPC Status Screen

a. Is the Item Status indicated on the CPC Status Screen?
4. CPC Manual Screen

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a. Is the Item Status indicated on the CPC Manual Screen?

5. CPC Main Logic

a. Is the item used in the CPC main Script?
i. Choice: Yes, No, N/A
6. CPC Start Run Logic

a. Is the item used in the start run script?

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7. CPC Live Test

a. Does the Item function when operated on in CPC?
i. Choices: Yes No, N/A (only spares).
8. Field Test
a. Was this channel tested in the field?
i. Choices: Yes No, N/A (only spares).
9. Comments
a. Note any comments or special conditions that occur.
10. Shop Testing is not complete until all check fields with the exception of the ones located under the
Field Test are checked with a Y or an N/A.
a. No N should be visible on the IO list by the end of testing.

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11. The I/O List is not complete until every cell is marked with a Y or a NA.
a. No N should be visible on the IO list by the end of testing.

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Chapter 9 – Flashing the PLC
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Chapter 9 Flashing the PLC

Flashing processor using CF Memory card
What is this document?

This procedure shows how to flash an Allen Bradley CompactLogix PLC using a pre-programmed
CompactFlash memory card. This is so you don’t have to use ControlFlash and BOOTP to configure the
device.
The process will:
- Update the processor’s firmware.

- Assign an IP address to the controller so it can be programmed using Ethernet.
This setup is for CompactLogix 1769-L32E and CompactLogix 1769-L35E processors.
What you will need:

1. New processor (L32E or L35E).
2. Master memory card. ASC has two pre-programmed CompactFlash cards – one for each processor.
3. CompactLogix right endcap and power supply (wired to 120V). These should be in the testing
room/office.
Flash Processor
1. Connect the processor’s battery.
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2. Connect the PLC processor, power supply, and right endcap.
3. Insert the master memory card into the processor.

4. Place key in REMOTE mode (center position).
5. Turn power on. The CF and OK lights should flash red, indicating the firmware is being flashed.
6. Wait until all lights are green. This should take about 5 minutes. Do not touch the processor or
remove power during this process.

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Run Program
1. Once the flashing process is complete, turn key to RUN mode.
2. Wait at least 1 minute for the program to run. It will automatically assign the IP address 192.168.5.20.
Flash new firmware to the processor using RSLogix

Any new processor must be flashed. You can do it from RSLogix 5000.
1. Before flashing firmware, make sure everything is properly connected and your laptop is plugged in. If
the process is interrupted by loss of power or disconnection, the processor may be permanently
destroyed.
2. Make sure the processor key is in Program Mode. Flash will not work if in run mode.
3. In RSLogix5000, Select the tab at the top ‘Communications Who Active’ and a window will pop up.
Expand the following…
a. AB, ETH-1, Ethernet
i. 192.168.5.20,1769-L35E Ethernet Port, ….
1. Backplane, CompactLogix System
Select ’00,CompactLogix Processor, 1769-L……’ and the buttons at the right of the window will now
be selectable.

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4. Select ‘Update Firmware’. An update firmware window will pop up. Follow the steps to begin the
update. Note: this process will take a few minutes to complete. If the progress bar has not moved for a
few minutes, give it some time. This process can take up to 10 minutes to complete.
5. Once the firmware has been updated, you will download the program you have created in the previous
steps. Return to the ‘Who Active’ window from step 3 and select ‘Download’. A new window will pop
up. Follow the steps to complete the program download.
Check PLC after Flashing:
Check Processor
1. Connect your PC to the PLC processor using a crossover cable, or a regular Ethernet cable into the
Ethernet switch.
2. Assign your PC’s Ethernet adaptor a static IP address within the 192.168.5.X range.
- Go to Control Panel > Network and Sharing Center > Network Connections.
- Open Local Area Connection. Go to Properties.
- Open “Internet Protocol Version 4 (TCP/IPv4)”.
- Assign a static IP address within the 192.168.5.X range.

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- Click OK and exit.
3. Ping the PLC’s Ethernet adaptor.

- Go to Start, type “cmd”, then enter.
- Type “ping 192.168.5.20”, then enter.
You should see “Reply from 192.168.5.20”.
4. Check the processor in RSLinx.

- Open RSLinx and find the processor.
- The processor should display the program name “Blank_L32E” or “Blank_L35E”.

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- Right click on the processor, select “Device Properties”. The revision should be 20 or higher.

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Copying an Existing CompactFlash Memory
Memory card requirements:

The CompactFlash card must follow these requirements:
- The card must use FAT16 file format.

- Maximum supported card capacity is 1 GB.
Allen Bradley suggests using their part number 1784-CF64 or 1784-CF128. If another manufacturer’s card is
used, it is possible that it will not work at all.
How the PLC Uses a CF Card:

A CompactLogix PLC processor has its own internal memory, but an external CompactFlash card may be
used to store a backup image, or to update the project inside the PLC.
On power-up, the processor first checks the CF card’s settings to determine what to do. It will check:
a. Should the processor update its firmware from the memory card?
b. Should the processor load the project from the memory card?
This information is stored on the memory card itself.
Changing a PLC’s installed program using a memory card:

You cannot program a CF card directly from an RSLogix project. The project must always be programmed to
a controller first. You can, however:
a. Use a PLC processor to store a project image directly to a CF card.

b. Copy an existing card’s contents and save them to a different card using a computer with CF
card reader.
Storing a new PLC project to a memory card:

To copy a new project, use the following steps:
1. Open RSLogix and connect to the processor.

2. Go to Program Mode.
3. Right click on the controller and go to Properties > Nonvolatile Memory > Load/Store.

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4. Change the following settings:

Load Image – On Power Up
Load Mode – Program (Remote Only)
Automatic Firmware Update – Enable and Store Files to Image
5. Click Store.
How to duplicate a memory card:

1. Insert the Master Card in card reader. Copy contents to PC.

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2. Insert new card in reader. Copy the “Logix” folder to the card.
3. Done. You can now use this card in the PLC.

Chapter 10 – VFD Setup
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Chapter 10 VFD Setup
VFD Setup manual

This is a basic overview. For more detailed instructions and troubleshooting, refer to document #60608.
Before Power-up
1. Confirm all inputs are connected and the terminals are secure
2. Verify that the stop input is present or the drive will not start.
3. Set the DIP switches. Switch 1 should be on, and switch 2 should be off. The switches are accessed
by removing the panel cover.
4. Verify that the 480v power leads are tightened and secure
5. Verify that inspection was completed on the panel.
Setting Parameters
Once the VFD is powered, press “PU/EXT” to go into PU mode to change settings.
1. To select a parameter to change, rotate the selection dial and then press the “Set” button.
2. Rotate the dial to change the value of the parameter.
3. Press “Set” again to save the setting.
4. The screen will flash between the parameter and the value that it is set to.
Parameters
1. Pr 570: Multiple Rating Setting. Set to 1: Light Duty
2. Pr 1: Maximum Frequency. Set to the motor frequency, (refer to motor nameplate) usually 60Hz.
3. Pr 2: Minimum Frequency. This should be set to 0Hz
4. Pr 3: Base Frequency. Set to the motor frequency, (refer to motor nameplate) usually 60Hz.
5. Pr 7: Acceleration Time. Set to 20s. Refer to the setup manual for this formula.
6. Pr 8: Deceleration Time. Set to 20s. Refer to the setup manual for this formula.
7. Pr 9: Electronic Thermal O/L Relay. Set to 1.1 * motor current rating (refer to motor nameplate)
8. Pr 19: Motor Voltage Rating. Refer to the motor nameplate.
9. Pr 22: Stall Prevention Operation Level. Set to the Motor Current Rating/ VFD Current Rating
10. Pr 55: Frequency Monitoring Reference. Set to the motor frequency, (refer to motor nameplate) usually
60Hz.
11. Pr 79: Operation Mode Selection. Set to 0: Ext/PU mode.
12. Pr 158: AM Terminal Function Selection. Set to 1.
13. Pr 195: ABC 1 Terminal Function Selection. Set to 99: Fault

Chapter 10 – VFD Setup
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14. Pr 196: ABC 2 Terminal Function Selection. Set to 0: Motor Running
15. Pr 250: Stop Selection. Set to 2: Coast to stop after 2s
16. Pr 267: Analog Input Selection. Set to 0: Current input.
Summary of Standard Settings
Parameter Setting/Option Description
570 1 (Light Duty) Multiple rating setting
1 [e.g. 60Hz] Maximum frequency (Hz). Set to motor frequency.
2 0 Minimum frequency (Hz)
3 [e.g. 60Hz] Base frequency (Hz). Set to motor frequency.
7 20 Acceleration time (seconds)
8 20 Deceleration time (seconds)
9 [e.g. 330 * 1.1 = 363] Electronic thermal overload relay (motor overload from
nameplate * 1.1)
19 [e.g. 480V] Motor voltage rating (volts). Refer to motor nameplate.
22 [e.g. 188A/250A = Stall prevention operation level. Set to Motor Current Rating
75%] (nameplate)/ VFD Current Rating.
55 [e.g. 60Hz] Frequency monitoring reference. Set to motor frequency.
79 0 Operation mode selection
158 1 AM Terminal function selection
195 99 (Fault Status) ABC1 terminal function selection
196 0 (Motor Running) ABC2 terminal function selection
250 2 s (Coast to stop) Stop selection
267 0 (4-20 mA) Analog input selection

Chapter 11 – Panel Test IN13
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Chapter 11 Panel Test IN13
IN13 and IO List

The Electrical Panel Inspection Report-IN13 is a step-by-step checklist for conducting a Panel Test. It can be
found in OMS as document number 37381. Also, The IO List should be created already. See the I/O list portion
of this document.
Electrical Drawings
In order to conduct a Panel Test you will need the most up to date electrical drawings for the project. In many
cases there are several revisions of these drawings and if yours is not up to date, that can lead to errors when
conducting the inspection. Request the drawings from Document Control and inform them it is for ‘Inspection
Only’.
Electrical Inspection
Before beginning the inspection, the main breaker must be locked out, and tagged out. Verify that the main
phasing is correct, and the main breaker is the correct voltage. Check the transformers are wired correctly.
Turn all breakers to the off position.
Check all electrical components for the correct size and label. Physically verify that all connections are tight by
giving a tug on the wire. If a component needs to be set to a certain voltage or other setting, make sure it is set
according to the drawing.
Identify Errors
If an error or mismatch from the work to the drawings is found, circle it and write down a quick description of
the error. Once the page is completed, Sign and date/time the page.
Things to Check For:

• Correct components (circuit breaker, motor starter, relay, etc.)
• Correct component specs (must match electrical drawing)
o Voltage
o Current rating
• Correct wiring, correct wire numbers
• Missing wires, missing bridges (yellow bars spanning multiple terminal blocks)
Only after everything has been visually and physically verified, apply voltage. Measure the control voltage and
compare with electrical drawings.
Non Conformance Report (NCR)

For any changes or fixes to be addressed, a NCR form must be issued. You must fill out a Pre-NCR form
(#38405) and record all of your findings there. Once completed, deliver this form to the Electrical Fabrication
and Assembly Manager.

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Fill this section

and ‘Shop
Location’ only
PLC Program
The PLC program must be completed to continue. Follow the Procedure for Allen Bradley Programming
Document on the server for more information.
Check that all modules are configured, are the correct model, and installed in the correct rack/bank/slot. Check
that all I/O’s are entered correctly, per the electrical drawings and IO List. Check that all necessary logic is
present and correct.
Your laptop can now be connected to the Ethernet switch in the panel via Ethernet cable, or directly to the PLC
via crossover cable for downloading.

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Setting your PC’s Ethernet Controller (LAN Connection) to Static IP Address

1. Go to Control Panel -> Network and Internet -> Network and Sharing Center -> Change Adapter
Settings -> Local Area Connection.
2. Click “Properties”. Double click “Internet Protocol Version 4 (TCP/IPv4)
3. Click “Use the following IP address”, and then enter an IP address. This will be the static IP address
for your computer. Use 192.168.5.95 (or another address, as long as it is different from the PLC you
will be communicating with). Subnet mask should be 255.255.255.0, as shown below.
4. Click Ok.
Setting IP address on new PLC processor (using BOOTP)

Before programming a new processor, it will need to be set up with BOOTP to assign an IP address. If the MS
(Module Status) light is blinking and the NS (Network Status) light is not lit, then the device does not have an
IP address and it is running in BOOTP mode.
1. Disable wireless on your laptop before using BootP to make sure you are only accessing the PLC.
2. Connect cross-over cable from laptop to PLC processor or standard patch cable from laptop to
network switch and a batch cable from the switch to the PLC.
3. Run BootP in RSLogix Program Files.
4. Configure Subnet Mask (255.255.255.0) if requested.
5. Look for MACID in “Request History”. You may have to wait a minute for anything to show up.

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6. Verify this MACID with the label on the processor. You will have to open up the battery cover on the
side of the PLC to check this label.
7. Select the MACID, and then click “Add to Relation List”.
8. Enter a new IP address for the processor. For example, 192.168.5.20 is commonly used. Check the
control wiring schematic for the correct IP address to assign.
9. Once IP address is set, click “disable BOOTP” on the processor until successful (success message
will be shown on the bottom of BootP. (Warning: once the processor has been disabled, it will no
longer broadcast to BootP to allow configuration in this manner.)
10. Power down and power up PLC processor. Wait 30 seconds or so until the PLC is fully running.
11. Check the IP address with Ping:
a. Open the command prompt (click the start key, then type “cmd.exe”, then enter).
b. Type “ping 192.168.5.20”, then enter. The program should ping the PLC 4 times without
timing out.
Forcing I/O through Local Tags

1. Now you are able to go online with the PLC. In order to force the PLC I/O we will need to go into Run
mode and enable I/O Forcing. At the top left corner you will see ‘Offline, NoForces, and No Edits’.
Make sure the PLC is manually switched to ‘Remote Mode’ (the switch on the front of the PLC) and
click the following…
a. ‘OfflineGo Online’
b. ‘OfflineRun Mode’
c. ‘No ForcesI/O ForcingEnable All I/O Forces’
2. We must now locate the Local Tags where we will bump the PLC I/O. In the control organizer window,
expand ‘Controller …..’ and double click ‘Controller Tags’. Make sure the ‘Monitor Tags’ tab is selected
at the bottom of the page.

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3. The Local tags each represent a module on your rack. Each tag will have a number indicating the
corresponding slot. The tags will either have an I, C, or an O next to it. Make sure to expand the tag
that corresponds to the type of module you are forcing. If it is an input module then Open the tag with
an ‘I’ next to it. If it is an output module, select the tag with an ‘O’ next to it.

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Forcing Digital Modules (ON-OFF modules)
1. For Digial Output Modules (On/Off Modules) you will expand the local tag with an ‘O’ and the child tag
labelled ‘Data’. You will see two fields where the field on the left is the current I/O state (0= off, 1= on)
and the right field is the implemented force. You will input a 0 or 1 in the right field and hit enter. The
output should now be forced On or Off. When you are done, be sure to delete the force, instead of just
entering 0.

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Forcing Analog Modules (0-100%)

2. Analog Output Modules generally deal with 4mA-20mA for SCR’s or Pneumatic Positioner Valves
where 4mA is fully OFF/0% and 20mA is fully ON/100%. Anything in between will be an open value
between 0-100%.
a. You must input the forced values in units of µA. 4mA = 4000 µA and 20mA = 20000 µA
b. Enter the value in the field to the right and hit enter.
Output Testing
While using the Electrical drawings, enable each output from the PLC individually. Check that the correct
component turns on. Use a highlighter to mark the drawings for each correct output from the module to the
component. For analog outputs, measure the current on a multimeter. Check that signal is getting all the way
to where it needs to go, through all connection points.

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Input Testing
While using the Electrical drawings, push all buttons, switches, etc. to check each input. For analog inputs, a
battery can be used to check wiring at the terminal blocks.
Thermocouple Testing
Check that the correct type of wire has been used for thermocouples. Typically, type J is red/white, and type K
is red/yellow. Make sure that the two thermocouple wires are soldered together at the end. Check the local
tags in the PLC. The reading is actually 10x the value, so if you are reading 752, it is 75.2°. If it is reading
1200, there is a wiring fault; most likely the wires have become unsoldered, or there is another open loop
somewhere. Rub on the thermocouple ends to check if the reading goes up. If it goes down, the wiring is
backwards.
Finishing I/O testing

Make sure that everything has been tested by checking your highlighted drawings. Record every Input and
Output on the IO List Spreadsheet. Remove I/O forces in the same menu as they were enabled (top left of the
PLC program, under No Forces). If any jumpers were used for testing, remove them.
Programming the High Limit Controller

In most cases, the Hi-Limit Controller is a Honeywell UDC120L
Select Mode
Select Mode allows you to enter the configuration and setup screens.
Hold and press to enter select mode.

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Configure Thermocouple Type and Scale

7. Use the arrow keys to select “Conf” (Configuration) mode. Press Setup to enter.
8. Use the arrow keys to select the unlock code, 20. Press Setup to enter.
9. Press Setup to scroll though parameters. Go to “inPt”.
10. Use the arrow keys to select the desired setting for thermocouple type and scale. Typically, the
following may be used:
Type J, Celsius
Type J, Fahrenheit
Type K, Celsius
Type K, Fahrenheit
11. Press Reset to confirm the setting.
12. Hold and press to return to select mode.
Set Limit Temperature

1. Use the arrow keys to select “SetP” (Setup) mode. Press Setup to enter.
2. Use the arrow keys to select the unlock code, 10. Press Setup to enter.
3. Press Setup to scroll though parameters. Go to “SPuL” (Setpoint Upper Limit).
4. Use the arrow keys to select the temperature value that the controller should alarm at. This is typically
50 degrees F above the maximum temperature setpoint of the vessel.
5. Press Reset to confirm the setting.
6. Hold and press to return to select mode.
Return to Operator Mode (Main Screen)

Use the arrow keys to select “Optr” (Operator) mode. Press Setup to enter.
Watlow EZ-Zone Limit Controller

For Bond controllers, a Watlow EZ-Zone controller is usually used. You will need the cable, and program/driver
CDs. Included in the software is a setup video.

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Clean-up
Now everything has been tested and verified, take another look through the PLC code. Make sure everything
matches the drawings. Make sure everything is used, and if it isn’t, delete it. Make sure everything makes
sense and works.
Remove all jumpers and reconnect everything that was disconnected for testing. If any relays or other
components were swapped for testing, make sure the proper ones get back in place. Replace the wire way
covers. Make sure everything is ready to ship.
Make sure that all NCRs have been reported and noted on the IN13, and that all tested IO have been marked
on the “IO List” Excel spreadsheet.

Chapter 12 – Cooling Check
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Chapter 12 Cooling Check

Autoclave Cooling Check
Cooling is an essential part of the autoclave cure process. There are several locations where water can leak
from the system and if there are any leaks, this can affect the cooling rate as well as the heating rate. This is
why performing a Cooling Check is an essential part of an autoclave startup. This procedure assumes that the
cooling pump and valves have been properly configured and confirmed working. A P&I check should also have
been performed confirming the proper connection of the cooling system.
Visual Pre-Check
One of the easiest ways to leak water from the autoclave is by having a pipe connection point not fully
tightened or some sort of drain valve opened. First confirm with the mechanic assigned to the job that the
cooling lines are ready to go and proceed with your visual inspection that everything is connected properly and
all drain valves are closed (Drain tank, Cooling tank).
Fill the Cooling Tank (if applicable)

Filling the cooling tank will take time. Depending on the size it can typically take 15 minutes to up to an hour.
Get the assigned mechanic to fill the tank for you.
Before You Begin

Open all isolation valves in the cooling line to make sure water can flow. Refer to the list below for places to
check. Make sure to keep the capsule door and autoclave door open.
Note: Depending on the autoclave configuration there may be more or less cooling isolation valves at these or
other points in the system.
• Main Cooling Valve

• Trim Water Valve
• Main Cooling Pump
• Capsule cooling line
• Drain Tank (If applicable)
• Tower Cooling Pump (if applicable)
Note: If the system has a cooling tower, go ahead and give the tower return line a few jiggles/shakes. A leak
here won’t affect the autoclave but will make a mess for you should one of the joints pop off.

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Begin Cooling
Start the main cooling pump and make sure all valves that operate during cooling phase are open (Main Cool
valve, Trim water valve, capsule cooling valve [if applicable]). Sometimes the valves get installed backwards,
so they are open instead of closed, etc. Checking this now will save you time and headaches later. Save the
drain valve for later. If left open you could overfill the drain tank.
Inspection
Immediate Piping Inspection

Quickly do a full walk around to make sure there are no major leaks. Major leaks will become apparent almost
immediately after the water lines are filled.
Full Piping Inspection

If there are no major leaks occurring it might take several minutes for other leaks to present themselves. Wait
about 10-15 minutes and then check pipe by pipe to make sure no water is leaking/dripping. It’s good practice
to physically feel around junction points for moisture.
Important inspection points

All leaks are important and must be addressed but there are two major areas that must be inspected several
times.
1. Coiling Coils: If there is a break in the cooling coils then a leak can appear anywhere but in most cases
the coils are fine. You need to monitor the connection point behind the cooling coils.

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2. Fan Capsule: Just as the main cooling coils, if there is a break in the capsule cooling coils then the
leak can be anywhere, but in most cases the leak will reside near the flex tubing as seen in the second
image below.

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Check Ball Valves

Sometimes valves will have no issues when they are open but once they are closed water leaks. This is more
apparent in manual hand operated ball valves or pneumatically actuated valves. To test this manually operate
the valves repeatedly a few times. Make sure the cooling pump is running. Check for moisture.
Continue Running
After you have gone through the inspection, allow the cooling system to continue running for about 30
additional minutes. After that time if there are still no leaks then the system has passed the cooling check.

Chapter 13 – Heater Check
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Chapter 13 Heater Check

Autoclave Heater Check
Heating is an essential part of the autoclave cure process. There are several components in the heating
system where if a fault should occur in any of them while running the system, you can receive damage to the
equipment or even start a fire inside and/or outside of the autoclave. This is why performing a Heater Check is
an essential part of an autoclave startup. This procedure assumes that the Heaters (SCR,SSR) have been
properly configured in the PLC and CPC logic. An Electrical component check should also have been
performed confirming the correct components are being used. The main breaker that energizes the Power
panel must be locked out with your lock to prevent accidental injury or death.
Insulation Resistance Testing with SCR

The flow of current through a resistive element radiates heat. Heating up an autoclave requires a lot of current.
It can be several hundred amps depending on the size and heating requirements of the system. It is very
important to test the insulation resistance integrity of the wiring going from the heating elements to its source of
power. Failure to do this can potentially lead to equipment failure, fires, or injuries to anyone who is around.
The insulation tested is shown below. The portion within the red circle is the ceramic mounting lug of the
heater, which serves as insulation from the metal chassis the heater is mounted on.
General Layout
The general layout of a heating system with an SCR is illustrated below. The image may differ slightly from
your configuration but the idea is the same. You will have a contactor which allows the SCR/SSR to become
energized, an SCR/SSR which varies the amount of current to flow to the heater, and the Heater which
converts electrical current into heat.
Confirm that 2 legs from the contactor feed through the SCR and follow through to the heater, and that 1 leg
goes straight from the contactor to the heater, as shown in the figure below.

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Insulation Megohm Testing

To test insulation integrity of a wire you will need a Megohm meter. THE CIRCUIT MUST BE DE-
ENERGIZED. With the meter you will apply a 1000V signal into the copper portion of the wire and get a
resistance reading on the common ground of the panel. The readings will be in the Mega Ohms range and will
depend on your wire length and heating element design. A reading from a 10x30’ autoclave was about 3MΩ.
The reading will vary largely based on circumstance and phenomena, but anything below 1MΩ will indicate a
problem.
The figure below shows the positive red lead of the Megger (Megohm meter) is on the bare copper portion of
wire 4 and the negative black lead is touching the panel ground. Any bare piece of metal that is screwed into
the panel chassis will do as ground (see Figure Megger 1). When the leads are at position make sure the
megger is set to 1000V and then press the test button (the device and/or the red lead will have a test button). If
all is well you will get a large value (generally greater than 1MΩ). Record it and do the same for wire 4 and 5.

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Heater Diagram – Insulation Testing
Figure Megger 1 The ground clip of the megger connected to one of the grounding lugs of the panel.
Figure Megger 2a & 2b The megger's red lead connected to wire 2 from the heater diagram and the megger's reading
(4MΩ, and a 4V drop.)

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Figure Megger 3a & 3b The megger's red lead connected to wire 4 from the heater diagram and the megger's reading
(4MΩ, and a 4V drop.)
Examining Voltage Drop

To further evaluate the integrity of the heater, examine the voltage drop shown across the insulation. The test
shown above used a 1000V test signal, and a 4V drop occurred. If the megger reads above 95% of the test
signal, the test is good. In the case of a 4V drop from a 1000V test signal (0.4%), and 4MΩ, the test was
excellent.
What resistance value is acceptable?

Generally, a good value for resistance is anything above 1MΩ. However, new heaters, which have never been
used before, have shown to have resistance readings of as low as 200kΩ. This is probably due to prolonged
storage and moisture accumulation within the insulation. These heaters should be NCR’d and appropriate
action will be decided as to test or scrap them. The table below shows an example of readings.
Resistance Voltage Drop (from a 1kV signal) Result/Action

2MΩ 10V Good, Go for Test
<1MΩ 30V Possibly good, NCR
<1MΩ 750V Bad insulation, NCR
<1MΩ 990V Short is present, NCR
Element Resistance testing

Testing the resistance of the heater elements will give a good indication of the health of the heaters when
compared to their calculated values. A really high resistance reading will indicate faulty heaters that will have
difficulty heating. A really low resistance will indicate heaters that may be faulty and heat up too quickly. A
ZERO reading will indicate a damaged or short circuited element.
Test 1
For the first test you will need a standard multi-meter set to resistance ohms readings. You will check the
resistance readings from all combinations of phases (1-2, 2-3, 1-3). All three values should be the same as
each other less than an ohm different. The diagram and figures below show the test in action.

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Figure Resistance 1 Testing terminals 1 & 2. Reading: 3.2Ω

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Test 2
The second test is to compare the reading from the last test and compare it to the calculated theoretical value.
Using the formula below, calculate the theoretical resistance of R1 and compare that to the actual reading you
got in the previous step. Note: This is a balanced load so R1,R2,R3 should equal each other. The voltage and
the Watts required for the calculation are written in the Power Wiring Schematics.
3(VL2 )
W DELTA =
R1
R1=R2=R3
Begin Testing
At this point you have completed the heater check and have determined that the heater is safe/unsafe to begin
testing.

Chapter 14 – Fan Check
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Chapter 14 Fan Check
Fan Direction
In order for the autoclave to properly distribute hot and cool air, the fan needs to run in the proper direction.
The fan sucks air from the center of the autoclave, and pushes it out towards the outside walls. As the blower
wheel rotates, the wheel circumference must slap the air.
Viewing from the autoclave door, the rotation should be one of the following:
If the fins lean to the right
Then, the rotation must be Counter Clockwise (CCW)
The picture to the right shows a wheel that must rotate Counter
Clockwise. Notice the angle of the fins on the wheel.
If the fins lean to the left
Then, the rotation must be Clockwise (CW)
Airflow
In order for the heating and cooling rates to be met, the airflow must be high enough. When the mechanical
engineer designs the system, the calculations used to choose a fan are posted on the server in the job folder.
Open this file and see what the airflow under the floor should be. Use an anemometer to meter the average
airflow under the floor, directly in front of the cooling coils. If it is not high enough, it might not meet cooling
rate.

Chapter 15 – Calibration & Certification
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Chapter 15 Calibration & Certification

Calibration Equipment
Metrology standards (Pressure/Vacuum, Thermocouple)
Pressure/vacuum hand pump
Poly tubing with fittings
Thermocouple jumper wires (Type J, Type K)

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Getting Calibration Equipment

1. Check out a calibration kit from document control.
2. Verify that the calibration period for pressure and thermocouple calibration standards has not expired.
If either has expired, return the entire kit to the Quality Department and request a new one. Calibration
standards cannot be mixed from different calibration kits – the entire kit must stay together.
Verify expiration date
Calibration
Pressure Calibration
1. Verify that the equipment’s required pressure range does not exceed the range of the calibrator. (300
PSI is the maximum pressure range of the calibrator used by ASC).
2. Connect the poly tubing to the pressure calibrator, hand pump, and transducer’s 3-way valve. Turn
the valve to calibration position.
3-way calibration
valve should point to
external port
3. Set the calibration hand pump to “pressure” mode by pushing in the pin. On the hand pump, turn the
small knob counterclockwise to vent the line.
4. Turn on the pressure calibrator and select the correct units (usually psi).

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5. In CPC, go to Support > Calibration Screen. Click on the sensor to open Quick-View. Select
“Calibrate”. Enter the low value (0 psig), then set.
6. Close the hand pump vent knob, then pressurize to the high sensor range (e.g. 150 psig)
7. Monitor the calibrator and verify that pressure does not drop rapidly, indicating a leak. Do not
calibrate the transducer until leaks are fixed.
8. Check the sensor value in CPC to make sure the transducer is reading pressure. If not, rotate the
calibration handle – it may be installed backwards.
9. Follow the CPC instructions to complete calibration, or refer to ASC document 31346 – CPC
Calibration & Certification Manual.
Vacuum Calibration
1. Connect the poly tubing to the calibrator and hand pump. Set the calibration hand pump to “vacuum”
mode by pushing in the pin. Turn the small knob clockwise to close the valve.
2. Turn on the pressure/vacuum calibrator and select units (usually inHg).
3. Connect to calibration line:
For separate calibration probe lines (e.g. system vacuum), Connect as shown in pressure calibration
step 2.
For common calibration network:

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a. Verify the 3-way valve handles have been installed the correct direction.
b. Connect the poly tubing to the EXT port.
c. Turn “CAL SOURCE” valve to “EXT”.
d. Turn “CAL SELECT” to VAC”.
e. Turn all probe calibration valves to “CAL” position.

4. Pull full vacuum with the hand pump.
5. Verify all probes are reading vacuum. If a probe is reading the same value, turn the probe’s
calibration valve handle to verify it has not been installed backwards.
6. Monitor the calibrator reading and verify that vacuum does not drop rapidly, indicating a leak. Do not
calibrate the transducers until all leaks are fixed.
“Calibrate”. Follow the CPC instructions to complete calibration.

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Thermocouple Calibration
1. Switch Thermocouple calibrator to “Source”.
2. Click the knob twice to enter setup.
3. Select correct temperature units.
4. Select the correct T/C type.
5. Verify that CJC (cold junction compensation) is ON. Click Exit.
6. Switch the temperature selector to Low position. Turn the knob to the low sensor range, usually 70
degrees F. Click and hold the knob in to store the value.
7. Holding the knob down while turning it will allow you to jump 10 degrees per increment.
8. Switch the selector to High position. Enter a high value, typically 50 degrees F above the max
equipment operating range. Store the value.
9. Connect the thermocouple wire jumper to the calibrator. Verify that the TC wire is the correct type.
10. For thermocouple Jacks (Part TCs): Plug the calibrator into the T/C jack.

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11. For thermocouple capsules (Air TC): Open the TC capsule, disconnect the wires, and connect to the
calibrator using the small jack from the jumper wire.
Disconnect Attach wire

wire from using small
capsule. jack.
Calibrate.
13. Switch the calibrator to “Low” range (e.g. 70 degrees F).

14. In the “Calibrate Sensors” window, verify that the PLC input value is within 1.5 degrees F of the
calibration standard. If not, there may be an issue with the PLC card or CJC jumper. See section 7.9 -
Troubleshooting Calibration Issues.

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Raw PLC input

value
Calibrated
value
15. witch calibrator to “High” range. Verify raw PLC value as shown in the previous step.
16. Switch to low range . Follow CPC instructions to complete calibration, or refer to ASC document
31346 – CPC Calibration & Certification Manual.
Certification
Pressure and Vacuum Certification

1. In CPC, go to Support, then go to the Pressure Certification or Vacuum Certification screen. Enter the
required information:
a. Select First Sensor and Last Sensor you would like to certify.
b. Auto Cert Values – this will usually be 3 values to test the full range of the transducer and
make sure output is linear.
c. Tolerance – this is based on the transducer’s rated accuracy and the customer’s
requirements. Typically +- 1 psi for pressure, and +- 1 inHg for vacuum are used.
d. Certification Operator
e. Report Comment – type the following from your calibration standard:
- ASC asset number

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- Serial number
- The standard’s due date
For example, “Traceable to NIST Standards. ASC# 3433 S/N 1831032 Due 2015-01-20”
c. Cert Expiration Date – usually 1 year from the current date.
2. Connect the calibration equipment and generate the first pressure or vacuum test level using the hand
pump. Confirm the correct level with your calibrator.
3. Start the certification.
4. The certification will log the value for each sensor that is within tolerance, and display “Fail” for each
value that has not been confirmed yet.
5. For pressure and vacuum certification, you will need pause the certification between each test level.
Otherwise, CPC may log an incorrect value while you are still making adjustments to the
pressure/vacuum level. Start the certification again once you adjusted to the correct level using you
calibrator.
6. End the certification once all values have been tested.
7. Save the report. Print a copy of each report to XPS file so they can be easily viewed or printed later.
Keep these reports to turn into document control.
Thermocouple Certification
1. In CPC, go to Support > Temperature Certification. Enter the required information:
a. Select the First Sensor and Last Sensor
b. Auto Cert Values – this will usually be 3 values to test the full calibrated range.
c. Tolerance – typically +- 1 degrees F.
d. Certification Operator
e. Report Comment – type the following from your calibration standard:
- ASC asset number
- Serial number
- The standard’s due date
For example, “Traceable to NIST Standards. ASC# 3433 S/N 1831032 Due 2015-01-20”
f. Cert Expiration Date – usually 1 year from the current date.

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2. Verify the calibrator’s settings per Thermocouple Calibration steps 3 to 5.

3. Set the Low, Mid, and High values on the calibrator so you can easily switch between values. Plug the
jumper wire into the first thermocouple jack or connect to the capsule wire per Thermocouple
Calibration step 11.
4. Start the certification. After the value is confirmed (showing blue), you can switch to the next value or
sensor without pausing the certification.
5. End the certification when all sensors have been tested.

6. Save the report. Print a copy of each report to XPS so they can be easily viewed or printed later.
Keep these reports to turn into document control.
Overpressure Switch Calibration

1. Verify 3-way calibration valve handle is pointing the correct direction.
2. Connect hand pump and pressure calibrator to the calibration port.
3. Verify that the switch is wired Normally Closed. The control power should be wired to common (C),
and the signal wire should be connected to the normally closed (NC) terminal. The signal should be
ON at ambient pressure.
4. Pressurize the calibration line to 10 PSI above the maximum pressure setpoint of the autoclave. This
will usually be 5 PSI below the vessel nameplate rating.
5. Set the pressure by slowly dialing up the setting until the signal turns OFF.
6. Slowly release pressure until the signal turns ON again.
7. Pressurize the line again slowly to verify that the switch activates at the correct pressure.
8. Attach a calibration sticker over the adjustment knob to make sure it is not tampered with. List the
date and value it has been set at.
Equipment Certification Documentation

1. Document the certification by completing the form # 53687 – Calibration Report.
2. Complete an ASC calibration sticker for each sensor (or group of sensors). Complete all fields and
include the sensor name, tolerance, and range.
3. Attach each sticker to the control panel.
4. Turn in the Calibration Report (53687) and each of the CPC certification reports to document control.
Refer to ASC document # 64614 – Product Calibration & Record Storage for recordkeeping requirements.

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Troubleshooting Calibration Issues

If thermocouple offset is more than 1.5 degrees F from the PLC value, there may be a problem with the CJC
jumper. Check to make sure the thin wire on the jumper is connected to the fork terminal and the wire is not
broken. Replace the CJC jumpers if required.
Small wire on
CJC jumper.

Chapter 16 – Vacuum Leak Check
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Chapter 16 Vacuum Leak Check

Procedure
Connect Vacuum Lines

On the inside of the autoclave, plumb each vacuum source line to a vacuum probe. All lines must be tested.
If there are an unequal number of probes and sources, multiple lines can be connected. All source lines must
be connected to a probe so that the leak rate can be measured.
Verify Calibration
Verify that all vacuum probes and system vacuum have been calibrated.
Check Vacuum Source Lines

If the equipment has a vacuum receiver, go to the Manual Operations Screen, then manually set the system
vacuum set point to full vacuum (-30 inHg).
If there is no vacuum pump or system vacuum receiver, temporarily connect a vacuum pump directly to the
vacuum source lines’ header and pull full vacuum.
Go to the Manual Operations or Vacuum Operations Screen.
Set each vacuum source line to “VAC” one at a time.
Verify that each probe connected to the source line is showing full vacuum.

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Check that all vacuum probes are displaying the same value as the system vacuum probe, within a 1 inHg
tolerance.
Run Initial CPC Leak Check

Go to the Run Operations Screen, then go to “Enter Batch”. Remove any existing parts from the batch, then
add a single part to the batch.
In the attachment selector, select all Probes and Source lines.
Go to Run Operations, then go to the Integrity Checks screen.
Setup an initial leak check to determine if there are any obvious leaks. For example, test 1 inHg in 5 minutes.

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Select “Start Integrity Checks”. Verify that the vacuum source valves shut off at the beginning of the leak test.
When the leak test ends, go to “View Leak Report”.
Look at the “Deviation” value. ASC vacuum lines must leak less than 1 inHg in 30 minutes.
Test Time.
Deviation.
Fix any obvious leaks, then retest as necessary.
Final Leak Check

Do a final leak check to make sure the leak rate is less than 1 inHg in 30 minutes.
Open the leak report. Verify that the final leak rate is less than 1 inHg in 30 minutes.
Required Documentation
Save and Print the Leak Report as PDF or XPS. Turn into document control or place in the Jobs folder.

Chapter 17 – Pressure Leak Test
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Chapter 17 Pressure Leak Test

Initial Walk Through
Description
The initial walk through is when you walk around the clave and check to make sure all glands, plugs and
fittings are completely tightened before initial pressurization.
Procedure
With the autoclave depressurized and the entire system powered down and LOTO, walk around the clave and
with a wrench ensure all glands, fittings and parts that the autoclave can leak are tightened. The glands are
delicate and must not be over tightened, as long as they are snug they should not leak. Some example of
areas that should be checked are illustrated below.
1. Check all Glands stated in IN9 which include fan motor gland, heater glands and TC glands.
a. Fan motor gland

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b. Heater glands
c. TC Glands

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2. Other areas to check for leaks include the safety relief valve, man in clave gland, dead ports and
anywhere leaks can occur. Some examples are included below but note that there may be leaks
elsewhere.
a. Safety relief valve
b. Man in Clave gland

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c. Dead ports including Dead port under the autoclave.

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d. Also check other areas of autoclave that can leak on autoclave such as the following example
Initial Pressurization
Description
Pressurize the autoclave to a low psi level and check for leaks.
Procedure
1. After initial walk through, setup the clave to be pressurized.
2. Make sure to keep the heaters and fan LOTO
3. Make a recipe that pressurizes the autoclave to 20 psi using a pressurization rate of 5 psi/min with a
hold time of 10 minutes.
a. A slow pressurization rate is required to reduce safety issues in case of a big leak.

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4. During pressurization check for leaks at the glands, tighten accordingly.

a. If there are any pressure leaks go in the “Run Operations Screen” and “End Run”

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b. Repair minor leaks or let a manager know about major leaks that can’t be easily repaired.
5. Once the desired pressure is reached and pressure in the autoclave is stabilized, verify that pressure
enable was shut off by entering the manual operations screen and verifying the Pressure Enable light
is off.
a. This will cause the exhaust and inlet valve to remain close, this is verified in the manual
operations screen as well.
6. Let the autoclave stay at desired pressure for 10 minutes with both inlet and exhaust valve shut. If the
autoclave leaks more than 0.3 psi in 10 minutes investigate where the leak is located and take
necessary precautions to repair it.

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7. Once the initial pressurization leak check is passed go onto complete the Pressure leak test.
Pressure Leak Test and Certification
Description
Pressure Leak test is designed to Certify the autoclave at a standard of no leaks greater than 1 psi over a 30
minute span at 100 psi.
Procedure
1. After initial pressurization, set up autoclave for Pressure Leak Test.
2. Make a recipe that pressurizes the autoclave to 100 psi using a pressurization rate of 5 psi/min with a
hold time of 30 minutes.
a. A slow pressurization rate is required to reduce safety issues in case of a big leak. Use
“CURR” twice so you get the most current temperature reading and the autoclave doesn’t cool
down to the previous temperature set point. Pressure changes with a change in temperature,
so the temperature must be controlled for this run. Make sure the fan, heater, and cooling
enable are all turned on.
3. Once the desired pressure is reached and pressure in the autoclave is stabilized, verify that pressure
enable was shut off by entering the manual operations screen and verifying the Pressure Enable light
is off.

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4. Let the autoclave stay at desired pressure for 30 minutes with both inlet and exhaust valve shut. If the
autoclave leaks more than 1 psi in 30 minutes like the example below, investigate where the leak is
located and take necessary precautions to repair it.

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5. Save the Data from the Run and the Run Report in the job folder under Data and Certifications as
“Pressure Leak Test and Certification”.
a. The data file should be under C:\ASC Data
b. In the “reports” tab of the reporting screen, choose which sensors need to be reported, and
print to XPS

Chapter 18 – PID
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Chapter 18 PID
PID Tuning in CPC
This topic sheet discusses the PID concept and tuning in CPC software.
What is PID?
PID, or “Proportional-Integral-Derivative”, is a common control algorithm used to control temperature, pressure,
and other processes. By using a PID algorithm, a controller or control system can control a complex process
and reach a zero-error state quickly, and with minimum process fluctuation (ie. overshoot).
PID terms
The PID algorithm includes three terms which are summarized to bring about the final control output:
PID
PID output = P + I + D
P = Proportional term
The proportional term is a component of the output that is based on the error of the process. In this
implementation, E, or error, equals the difference between setpoint and actual process value.
Pv = process value
Sp = setpoint
E = Error
E = (Sp – Pv)
Pg = Proportional Gain
P = E x Pg
I = Integral term
The integral term is the result of integrating the error over time. In general, this component is used to
correct small amounts of error that persist over a period of time.
Ig = Integral gain
Ti = time increment
I = SUM(E x Ig x Ti)
D = Derivative term
The derivative term is based on the rate of change of error. In general, this component is used to
correct the output for sudden shocks or changes to the process (ie. opening a door on an oven). This
term is seldom used on processes that don’t have shocks (ie. autoclaves, batch ovens, etc.)
Dg = Derivative gain
E1 = error at time increment #1
E2 = error at time increment #2
Ti = time increment between #1 and #2

Chapter 18 – PID
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D = (E2 – E1)/Ti x Dg
PID terms used by CPC

CPC’s PID algorithm uses a derivation of the classic PID algorithm.
PID output
Op = Output% due to proportional term
Oi = Output% due to integral term
Od = Output % due to derivative term
PID Output% = Op + Oi + Od, limited to range between 0-100%
CPC properties use for PID

The following properties are provided:
ProportionalBand – In units of process, this is used with BandOffset to derive the P term of the PID
equation.
BandOffset – In units of %, this is used to shift the proportional band. This setting can be considered a
“manual reset” and is used for split-range applications.
Reset – In units of %/minute/error, where error is in units of process. This is the integral gain used to
increase or decrease the resultant output due to integration of error.
Rate - In units of %/error, where error is in units of process. This is the derivative gain used to
increase or decrease the resultant output due to slope or change of error.
Op defined
E = Error = Sp – Pv, in units of process
Pb = ProportionalBand in units of process (property in PID object)
Op = Output% due to proportional term
Bo = BandOffset in % units. This property is used to shift the proportional band.
Op = (E / Pb x 100%) + Bo, limited to range between 0-100%
Oi defined
Rs = Reset, or Integral gain, in units of %/min/deg (or any other process unit)
Oi = Output% due to integral term
Ti = time increment between successive PID calculations, units = minutes
Oi = SUM (E * Rs x Ti) for each time increment. Note: calculation is only performed when 0 < Op <
100
Od defined
E1 = error of last calculation
E2 = error of current calculation
Ti = time increment between successive calculations, units = minutes

Chapter 18 – PID
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Rt = Rate, or Derivative gain, in units of %/change-in-error (error in process unit)

Od = Output% due to derivative term
Oi = (E2 – E1) * Rt. Note: calculation is only performed when 0 < Op < 100
CPC’s Output_PID Object
This generic object handles proportional PID control functionality.
Attachment
Used for configurations where this output is attached to a part. Typically this is only used on VacuumSource
line output types. The Attachment would be blank, 0, or a part #.
ControlMode
Control mode for the output.
Auto – AutoSetpoint is transferred to the MainSetpoint when the Do_Calc method is initiated.

Chapter 18 – PID
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SemiAuto –AutoSetpoint is not transferred to MainSetpoint when the Do_Calc method is initiated. The
MainSetpoint can be changed via screen icon on manual screen.
Manual – Outputvalue remains static and can be directly entered by operator via ObjectEditor or screen icon
link.
AutoSetpoint
Represents automatic setpoint that is routed to the MainSetpoint when the object is in Auto control mode. This
property is in the units of the process (ie. Deg.F) and is typically set by the Recipe_TempCntrl object during an
automatic run.
MainSetpoint
This property is the setpoint used for the PID calculations. It is in the units of the process (ie. Deg.F) and is
either set by the AutoSetpoint (Auto mode) or directly via a manual screen icon.
OutputValue
This property is the result of the PID calculation and represents a percent output to the heater SCR, valve, or
set of valves (split range). Note: If the BandOffset is 50%, than this output value represents a split range
controller where heating is 50-100% and cooling would be 50-0%.
PropBand
This property represents the proportioning band in units of process (ie. Deg.F). This band reflects the amount
of process change that will result in a 0-100% proportional output. With a zero BandOffset, the upper limit of
the proportional band is pegged to the setpoint. With a BandOffset of 50%, the proportioning band is centered
at setpoint. This results in the P term being 50% when the process reaches setpoint.
Reset
This is the integration gain and is in units %/Error/min where Error is in process units (ie. Deg.F). For
example, if the Reset = .5 and the process is deviating 10 deg.F, than the output will increase at a rate of .5 x
10 = 5 F/min. The additive integration amount is stored in the Integral property. The system will integrate up
or down until the output % is 0 or 100 or has reached the MinIntegral or MaxIntegral amount.
Integration only occurs once the process is inside the proportional band. No integration occurs outside the
proportional band and the Integral value is reset to 0 at that time.
Rate
Rate is the derivative gain and should only be used in applications where you expect a dramatic disruption in
control (ie. door opening on oven at elevated temperature). It should not be used for autoclave controls.
Rate is in units %/dError where dError is the rate of change of error (Deg.F/min) applied over the time period of
a scan. The derivative is applied instantaneously and does not integrate.
BandOffset
BandOffset is in percent units and represents a shift of the proportional band. If BandOffset is zero, than the
upper limit of the proportional band will be pegged to the setpoint. In this condition as the process approaches
the setpoint the output % due to P will converge on zero(0). If however you want the output to be 50% when
the process is at setpoint, than a BandOffset = 50 would be utilized.
BandOffset can also be used as a “manual reset” in that by increasing the BandOffset you will impose higher
percentage when the process reaches setpoint. For example, if your process requires 15% heating in order to

Chapter 18 – PID
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remain at setpoint, than for a split-range control you can set the BandOffset = 57.5 which will result in an
output of 57.5% at setpoint = 15% output to heater.
LastTime
This property is in seconds and is used internally by the object to calculate time intervals since last calculation.
LastError
This property is in process units and is used internally by the object to calculate the rate of error change for
use in derivative calculations.
Integral
This property is in % units and represents the amount of integrated output contributed by the I or Integral term
of the PID loop. Integral is created over time by the PID controller by multiplying the Reset value (see above)
by the error (Setpoint – Process Value).
Integral is only built-up while the process is inside the proportional band and is automatically set to zero
whenever the process moves outside of the proportional band.
Within custom scripting the Integral can be set, tweaked, or reset depending on dynamic considerations of the
process. This is often considered in ramping systems than cannot afford an overshoot. In the case of typical
ramp, the integral would have increased to a level that insures that the process is matching the ramped
setpoint. At the end of the ramp, the integral can be reduced or tweaked down to avoid the momentum affect
that can occur.
Do_Calc
This method is used to calculate the PID output%. This method is typically triggered by the parent Outputs
object’s Do_Calc method.
Do_Send
This method is used to transfer the Output property to the underlying IO object and to facilitate the IO method
call.
Do_Send
This method is used to transfer the Output property to the underlying IO object and to facilitate the IO method
call.
ForcedValue
This property is used with caution to force an output value. If a ForcedValue is entered, the Do_Send method
will send the forced output rather than the OutputValue. Extreme caution is urged in use of this property due
to likelihood of run-away conditions.
MaxSetpoint
This property is used to limit the setpoint and is in process units (ie. deg.F). The limiting occurs during the
Do_Calc operation and affects the MainSetpoint property only.
MinSetpoint
This property is used to limit the setpoint and is in process units (ie. deg.F). The limiting occurs during the
Do_Calc operation and affects the MainSetpoint property only.

Chapter 18 – PID
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MaxOutput
This property is used to limit the OutputValue and is in % units. The limiting occurs during the Do_Calc
operation. Note that the ForcedValue property will override any limiter.
MinOutput
This property is used to limit the OutputValue and is in % units. The limiting occurs during the Do_Calc
operation. Note that the ForcedValue property will override any limiter.
VariableMaxSetpoint
This property is an object path targeting a maximum setpoint entry in another object. If a path is entered, this
maximum setpoint is used as a secondary limiter to the MainSetpoint. This is typically linked to MaxAirTemp
or MaxPressure entry in the recipe segment object.
MaxIntegral
This property is in % units and represents a limiter on the Integral property.
MinIntegral
This property is in % units and represents a limiter on the Integral property. This property if used is typically
entered as a negative % value.
MinIntegral
This property is in % units and represents a limiter on the Integral property. This property if used is typically
entered as a negative % value.
TaskerForCalc
This property (name of tasker) if used restricts this output’s calculations methods to be performed only by a
specific tasker object.
TaskerForSend
This property (name of tasker) if used restricts this output’s send methods to be performed only by a specific
tasker object.
AutoSetpointSourcePath
This property is an object path that targets the setpoint value to be used for the AutoSetpoint property. If
entered, the Do_Calc method will pull the setpoint from this target and place that value in the AutoSetpoint
property prior to performing the calculations. In general the AutoSetpoint is usually “pushed” from another
action rather than “pulled” using this property.

Chapter 19 – CPC – IntegralScrubbing Object
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Chapter 19 CPC – IntegralScrubbing Object

Purpose of integral scrubbing
Integral-scrubbing is the act of reducing PID integral at the end of a heating ramp in order to reduce or
eliminate over-shoot of air temperature and/or uniformity thermocouple temperatures. Integral scrubbing is
usually only effective when a run is controlled by AIRTC (zero cascades) and the amount of scrubbing
changes with the relative value of the soak setpoint.
When CPC ramps air temperature at a specific rate, the PID output (AIRCNTRL) will windup the integral in
order to keep the AIRTC input on the ramped setpoint line. This integral works properly during the ramp, but
when the ramp has reached its goal, the integral now becomes a problem because it forces too much heating
and causes an overshoot. For this reason, it is wise to remove and/or reduce the integral as the ramped
setpoint approaches the setpoint goal.
The new IntegralScrubbing object manages all integral scrubbing logic and functionality needed for a
conventional autoclave or oven.

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IntegralScrubbing Object
The new IntegralScrubbing object is normally placed next to the RecipeProcessor object. The object has the
following properties and methods:
Enabled – This property enables or disables scrubbing.
ScrubbingPoints – This property sets the number of scrub points. You should set no less than 2 points.
Each scrubbing point is a set of three numbers indicating the setpoint range (ie. 250 F), the approach
deviation, and the scrub to apply to the integral. . The set of scrub points is held in the scrub table.
Array – This property holds the table array of scrub points. This array can be edited using the Edit method.
RecipeProcessorPath – this is set to the path of the RecipeProcessor object.

Example: .Autoclave.RecipeProcessor
TempControlPath – this is set to the path of the TempControl recipe segment object.
Example: .Autoclave.RecipeProcessor.RecipeSegment.TempControl
AIRCNTRLPath – this is set to the path of the AIRCNTRL output object.

Example: .Autoclave.Outputs.AIRCNTRL
PARTCNTRLPath – this is set to the path of the PARTCNTRL output object.

Example: .Autoclave.Outputs.PARTCNTRL
AIRTCPath – this is set to the path of the AIRTC input object.

Example: .Autoclave.Inputs.AIRTC
RunSatus – this is set by the system to the current run status (same as on RecipeProcessor)
ControlByAirTC – this is set by the system to indicate that the current run is controlled by air temperature.
Integral scrubbing will only be applied on runs controlled by air temperature.
AirTemperature – this is set by the system to indicate current air temperature.
Integral – this is set by the system to indicate current PID integral.
SetpointGoal – this is set by the system to indicate current ramp goal.
CurrentSetpoint – this is set by the system to indicate current ramped setpoint.
ScrubApproach – this is set by the system to indicate the current approach deviation value for the scrub. This
value is calculated from the scrub points table according to the current setpoint goal.
ScrubValue – this is set by the system to indicate the current scrub value for the scrub. This value is
calculated from the scrub points table according to the current setpoint goal.

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Scrub Table editing

After setting ScrubPoints value, click the “Edit” method to access the bias settings table.
The table shows the matching setpoint goal values and scrub values to be applied at each value. In the
example above:
For a ramp goal below 150 F, when the setpoint reaches to within 5 F of final setpont goal, an
integral of 2 will be applied.
For a ramp goal between 150F and 240F, an approach will be applied between 5 and 10 degrees,
and a scrub value will be applied between 2 and 7. These values will be calculated proportional to
the ramp goal position inside the range.
For a ramp goal between 240F and 350F, an approach will be applied between 10 and 20
degrees, and a scrub value will be applied between 7 and 20. These values will be calculated
proportional to the ramp goal position inside the range.
For a ramp goal above 350 F, when the setpoint reaches to within 20 F of final setpont goal, an
integral of 20 will be applied.

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Add IntegralScrubbing to main tasker

You will need to add a task to the main tasker. The task should have its method pointing to the
IntegralScrubbing\Calculation method.
Important: Also, make sure you add the task object below the PLCLogic task.

Chapter 20 – Post-Testing documentation and forms
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Chapter 20 Post-Testing documentation and forms
Shop Test Completion Form

The Shop Test Completion Form (ASC Item 64564) is completed by the control engineer(s) once equipment
testing has been completed at the ASC facility. The form is a checklist that ensures all the necessary data and
documentation related to shop testing has been uploaded to the server. A total of sixteen (16) items are
examined in the form. The directory they are uploaded to is:
Z:\ASC Jobs\”Job number”\Software\Shop Testing
Upon upload/completion of each item, a check is placed in the respective box on the form underneath the
column “Complete / Saved on server”. Each of the items are explained below.
1. Completed Shop Test I/O list. This is the I/O list generated with ASC Item 62600. The excel
worksheet is uploaded to the server upon completion.
2. “Final Meets” in OMS specs. This is the Final Meets Inspection – In House procedure.
3. Sensor calibration Certs and stickers. These are the sensor certifications from CPC’s
certification procedure. An XPS or PDF copy generated by CPC is uploaded
for each sensor that was certified. The stickers for each sensor are placed
inside the autoclave’s control panel.
4. Vacuum line leak test Cert. This is the certificate which shows the equipment tested did not
show any leaks during a vacuum line leak test. An XPS or PDF copy
generated by CPC to be uploaded. See Chapter 15 for further reference.
5. Vessel Pressure Leak test Cert. This is the certificate which shows the equipment tested did
not show any leaks during a pressure leak test. An XPS or PDF copy
generated by CPC to be uploaded. See Chapter 16 for further reference.
6. IN11 (ASC Item 37055). This is the IN11 safety procedure excel worksheet. The IN11 excel
worksheet is uploaded to the server upon completion.
7. IN9 (ASC Item 32293). This is the IN9 testing procedure checklist. The IN9 word document is
uploaded to the server upon completion.
8. Data from MAX temp MAX pressure. This is the data file from the maximum temperature and
pressure run that was performed on the equipment, per the test plan. In
addition to the .DAT file from CPC, an XPS or PDF copy generated by CPC is
to be uploaded.
9. Data from MAX temp rate. This is the data file from the maximum temperature rate run that
was performed on the equipment, per the test plan. In addition to the .DAT file
from CPC, an XPS or PDF copy generated by CPC is to be uploaded.
10. Data from uniformity run. This is the data file from the temperature uniformity run that was
performed on the equipment, per the test plan. In addition to the .DAT file from
CPC, an XPS or PDF copy generated by CPC is to be uploaded.

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11. Data from Temperature control. This is the data file from the temperature control run that
was performed on the equipment, per the test plan. In addition to the .DAT file
from CPC, an XPS or PDF copy generated by CPC is to be uploaded.
12. Data from Pressure control. This is the data file from the pressure control run that was
13. Data from Vacuum control. This is the data file from the vacuum control run that was
14. PLC CF Card Flashing. This item ensures that the PLC’s CPU was flashed to the latest
revision. A screenshot is taken in RSLogix5000, or whatever program was
used, which shows the CPU’s revision to be the latest. This screenshot is
uploaded to the server.
15. Daily Testing Diary. This item is a word document filled out by the controls engineer logging
the work completed, problems encountered, changes made, etc. for each day
of testing. If the engineer has logged everything in emails, the emails may be
uploaded instead.
16. Field Punch List (ASC Item 64562). This item is filled out if any work remains incomplete, is
to be tested in the field, or special instruction is to be noted for field testing
with the equipment.
In addition to uploading these 16 items, a verification is required of their upload. A second controls engineer
must check that the item has been placed in the appropriate directory on the server, and initial the respective
box on the form underneath the column which reads “Verified by.” This same engineer must then sign and date
the document in the field labeled “Peer check.”

Page 131 of 136
Final Meets Inspection

The Final Meets Inspections occur in two stages: In House (before shipping) and On Site
In House
The Final Meets Inspection – In House is the stage in which the product (autoclave/oven) is examined and
validated such that it meets all of the customer’s specifications. It is the ultimate stage of the product’s
inspection phase before shipping. The final meets inspection is typically carried out by the engineers who
worked on the autoclave. These include the mechanical, electrical, and controls engineer(s). Although it is not
necessary to have everyone present during the inspection, doing so is highly encouraged.
Procedure
To perform the final meets inspection, the spec sheet from OMS is required. Open OMS and select the job.
In the figure above, job 14405 has been selected from OMS. To view the spec sheet, click on the Specs button
in the lower left half of the screen, shown in the figure below circled in blue.
After clicking the button, the following screen appears.

Page 132 of 136
The figure above is the Job Specifications, also known as the specs sheet. The area of focus for the final
meets inspection is shown bordered in blue, with the final meets compliance checkbox shown in red. This is
the checkbox that will be filled out during the inspection. An enlarged image of the previously mentioned area
is shown below.
Once a user clicks either the yes or no checkbox, their name is automatically logged into the dropdown along
with a datestamp. If the checkbox is empty, the datestamp is removed, along with the name. This is very
important, as it is an official log of who performed the final meets inspection and when. Each engineer must
make sure their own name is in the dropdown when inspecting.
Three possibilities are possible from the final meets inspection.
1. Yes: ASC has fully met all the requirements as stated in the spec.

Page 133 of 136
2. No: ASC has not met all the requirements as stated in the spec.
3. Blank: ASC is working to meet all the requirements as stated in the spec.
An example of each scenario is shown below:
Yes
In this figure, the spec was fully met, as the vessel was certified PED during inspection.
No
In this figure, the spec was not met. The engineer has left a comment with their initials and date stating the
reason for the noncompliance. This is required for all “No” choices.
Blank
In this figure, the spec was not met at time of inspection. The engineer has left a comment with their initials
and date stating the reason for the noncompliance. This is required for all “Blank” choices. Also, all comments
for blank specs must be added to the Field Punch List (ASC Item 64562).
Once ALL the specs have been checked, the final meets inspection is complete. This means that if work is to
be performed on site (as in the “blank” example shown above on Page 3) the engineer must return to the
specs sheet, and check the appropriate box once the work is performed. It is also good practice to leave initials
and date when doing so. After all the work is done on site, the ASC engineer on site must speak with the
customer and perform the final meets inspection again. This stage is called Final Meets Inspection – On Site.
On – Site
The Final Meets Inspection – On Site is the stage in which the product (autoclave/oven) is examined and
validated such that it meets all of the customer’s specifications when on site. It is the ultimate stage of the

Page 134 of 136
product’s inspection phase after delivery and installation. The final meets inspection is carried out by a
representative of the customer, or the customer themselves.
Procedure
To perform the final meets inspection – on site, a hard copy of the spec sheet from OMS is required. Open
OMS and select the job.
In the figure above, job 14405 has been selected from OMS. To view the spec sheet, click on the Specs button
in the lower left half of the screen, shown in the figure below circled in blue.
After clicking the button, the following screen appears.

Page 135 of 136
The figure above is the Job Specifications, also known as the specs sheet. To print a hard copy of the specs
sheet, click the Print button on the top of the specs sheet, shown circled in red in the figure below.
Once a hard copy of the specs sheet is acquired, the inspection can begin.

Page 136 of 136
To perform the Final Meets Inspection – On Site, the customer must go through each of the paragraphs one by
one, and initial each paragraph. This is to ensure that a mutual understanding has been established between
both parties that ASC has met all of the customer’s requests. An example is shown below.
In the figure above, a sample is shown of the initials that would be put on site by the customer.
Once ALL the paragraphs have been initialed, the final meets inspection is complete. Afterwards, the hard
copy of the specs sheet is to be returned to ASC and turned into document control.

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Controls Engineering

Document #: 62590, Revision: ORG

Chapter 1 - Introduction ......................................................................... 11

Chapter 3 - Process Flow ....................................................................... 14

Chapter 4 - Pre-Testing Forms and Test Plan ....................................... 15

Chapter 5 - P&I Check ............................................................................ 19

Document #: 62590 Effective Date: 9/6/14 Revision: ORG

Chapter 6 - Creation of the I/O List ........................................................ 23

Chapter 7 - Procedure for Allen Bradley Programming ....................... 30

Document #: 62590 Effective Date: 9/6/14 Revision: ORG

Chapter 8 - Software Simulation ............................................................ 55

CPC Checklist Items ............................................................................................................................ 58

Chapter 9 Flashing the PLC ................................................................... 64

What you will need: .............................................................................................................................. 64

Flash Processor ................................................................................................................................... 64

Run Program ........................................................................................................................................ 66

Flash new firmware to the processor using RSLogix ........................................... 66

Copying an Existing CompactFlash Memory ........................................................ 70

Document #: 62590 Effective Date: 9/6/14 Revision: ORG

How the PLC Uses a CF Card: ............................................................................................................ 70

Changing a PLC’s installed program using a memory card: ............................................................... 70

Storing a new PLC project to a memory card: ..................................................................................... 70

How to duplicate a memory card: ........................................................................................................ 71

Chapter 10 VFD Setup ............................................................................ 73

Before Power-up .................................................................................................................................. 73

Setting Parameters .............................................................................................................................. 73

Summary of Standard Settings ............................................................................................................ 74

Chapter 11 Panel Test IN13 .................................................................... 75

Electrical Drawings .............................................................................................................................. 75

Electrical Inspection ............................................................................................................................. 75

Identify Errors ....................................................................................................................................... 75

Things to Check For:............................................................................................................................ 75

Non Conformance Report (NCR)......................................................................................................... 75

PLC Program ....................................................................................................................................... 76

Setting IP address on new PLC processor (using BOOTP) ................................................................ 77

Forcing I/O through Local Tags ........................................................................................................... 78

Forcing Digital Modules (ON-OFF modules) ....................................................................................... 80

Forcing Analog Modules (0-100%) ...................................................................................................... 81

Output Testing ..................................................................................................................................... 81

Input Testing ........................................................................................................................................ 82

Thermocouple Testing ......................................................................................................................... 82

Finishing I/O testing ............................................................................................................................. 82

Programming the High Limit Controller................................................................................................ 82

Select Mode ......................................................................................................................................... 82

Configure Thermocouple Type and Scale ........................................................................................... 83

Document #: 62590 Effective Date: 9/6/14 Revision: ORG

Return to Operator Mode (Main Screen) ............................................................................................. 83

Watlow EZ-Zone Limit Controller ......................................................................................................... 83

Chapter 12 Cooling Check ..................................................................... 85

Fill the Cooling Tank (if applicable) ...................................................................................................... 85

Before You Begin ................................................................................................................................. 85

Begin Cooling ........................................................................................................... 86

Full Piping Inspection ........................................................................................................................... 86

Important inspection points .................................................................................................................. 86

Check Ball Valves ................................................................................................................................ 88

Continue Running ................................................................................................................................ 88

Chapter 13 Heater Check ....................................................................... 89

Insulation Megohm Testing .................................................................................................................. 90

Element Resistance testing ..................................................................................... 92

Begin Testing ....................................................................................................................................... 94

Chapter 14 Fan Check ............................................................................ 95

If the fins lean to the left ....................................................................................................................... 95

Document #: 62590 Effective Date: 9/6/14 Revision: ORG