User`s Manual
Contents
1. The above mentioned values shall be given according to the transducer documentation Move the cursor to pressure calibration calibration of 0 mA Apply 0 mA current signal to connector specified as pressure sensor and accept with ENTER using the key set yes when answering question are you sure and again accept with ENTER calibration of 20 mA Calibration is carried out in the same way as above only applied signal shall be 20 mA As soon as calibration is complete press the ESC key three times Initialisation Use of this function results in deleting reports and clearing of recording buffer 4 7 Program parameters This function permits to store in memory or permanently modify settings of individual technological program parameters Modifications introduced using this function are stored in the controller non volatile memory The first operation during the programming is to select number of program that we currently wish to create or alter its parameters Then we set the following values technological program name tin code heating time pasteurisation time mi lt Ste 10 16 12 2002 The MCD 111 STERYLEX 2000 Microprocessor Controller User s Manual cooling time preset sterilisation temperature end temperature of water in the tank end temperature of tin sterilisation pressure sterilisation value F0 the Fp sterilisation value switchin2. each work cycle Special heating mode eliminates faults resulting from numerous variability factors occurring in industrial conditions Immediately after shutting the autoclave and pressing lt START gt button the unit continues its work automatically according to parameters of a selected program The initial phase of the process includes flooding workspace with water Water preheating the charge is warmed up according to the procedure which takes into account the initial temperature measured preset sterilisation pasteurisation temperature and specified time or required sterilisation coefficient value FO Desired temperature increase per time unit is computed on the basis of the data listed above Any deviation from determined temperature increase curve due to variability factors results in correction of a preheating program that is extending or shortening steam valve opening period Underheating in preset time e g due to too low flooding temperature or too short preheating time results in time extension by period required in order to reach the sterilisation pasteurisation temperature 3 16 12 2002 The MCD 111 STERYLEX 2000 Microprocessor Controller User s Manual During preheating there is natural pressure increase proceeding simultaneously with temperature growth Too low pressure as compared to preset sterilisation pressure value will be automatically corrected by opening of the compressed air valve At the end of the prehea
3. RYLEX 2000 Microprocessor Controller User s Manual lt F_19 gt reg p hist Dead zone of the pressure controller output lt F_20 gt exchanger Time of removing raw water from heat exchanger lt F_21 gt decanting time Water drain valve opening time in water decanting cycle counted from the moment of bottom level sensor switch off lt F_21 gt dosing pump 1 Time of dosing pump operation in the water filling cycle lt F_22 gt dosing pump 2 Time of dosing pump operation in the cooling cycle lt F_23 gt decanting time Water drain valve opening time in water decanting cycle counted from the moment of bottom level sensor switch off lt F_24 gt control type Permits to specify whether process controlling is to be carried out according to the t1 t2 t3 T formula or on the basis of temperature inside the can and measurement of the sterilisation value FO lt F_25 gt cooling type Cooling type selection cooling according to preset curve or cooling at maximum opening of valves lt F_26 gt T_min steril Minimum temperature which must be reached inside the can during sterilisation process lt F_27 gt T_min pasteur Minimum temperature which must be reached inside the can during pasteurisation process lt F_28 gt not used lt F_29 gt language selection The controller is operated in Polish and according to customer s order either in English or Russian lt F_30 gt auto
4. The MCD 111 AUTOKLAW Microprocessor Controller Version 1 00 User s Manual MiCSLER Sp z o o Ltd 41 250 Czelad ul Wojkowicka 21 Poland Tel 48 32 265 76 41 265 70 97 763 77 77 Fax 48 32 763 75 94 www mikster com pl mikster mikster com pl 16 12 2002 The MCD 111 STERYLEX 2000 Microprocessor Controller User s Manual TABLE OF CONTENTS PAGE 1 CHARACTERISTIC FEATURES OF THE UNIT cccsssssssssccesscssssscsssssssesscesseesseestestescsssesscscsesecseasecssesse 3 1 1 DESCRIPTION OF CONTROLLER OPERATIONS 0cccococcccncnononononononcnnnonononenonnnnnnnnnnnnnccnnnonononenncinnns 3 2 USING THE CONTROLLER snaren ccdvccecsdtoceleccdecotesscbcssoctdectassoubeusscsseutees0v ie oo OOO WII 5 2 1 MESSAGE DISPLAY SEE 5 2 2 WSINGIMENU ot ciate oe tt hice See A la dtd Sheath dee SA ro weet db ado heh os 5 2 3 SPECIAL KEYS AND MANUAL OPERATION KEYS cccccesccescesscssscssecssccseeceeeceeecesscesessesssesssessceascsssceascesecuscesesseess 5 3 MAIN MENU FUNCTIONS a cissisecccsccssaccscssecesacssscosereuecesnessvovuscusssoascoasendvsnvescesedssnseoseavscssscovassvebondcsbacsbaysuevenvesdcstecetoens 5 3 1 PROGRAM START AND S TOPS sc zaw ona ie acidos 5 3 2 PROGRAM SELECTION e oo ios 5 Bs SHE DITION a AL DA AO ea dal Sine ete ER ta de delat e WIA A A ae la ia ed 5 3 4 RESTART AND PROGRAM TERMINATION cc ccccccsscssscssecssecsecssecssssssesssesscusscssscsseceseceeecaeecsssessscssesssesssesscssceus
5. ation valve 45 compressed air valve 46 re circulated water draining 47 re circulated water supply 48 circulating pump 49 alarm 50 auxiliary valve for heat exchanger cleaning 51 dosing pump for liquid mi lt Ste 13 16 12 2002
6. clave type As regards adjustment of circulating water temperature during the cooling phase there are two types of autoclaves to choose from spraying type with exchanger we dose water of required temperature from heat exchanger to the autoclave spraying type without exchanger we dose cold water directly to the autoclave simultaneously adjusting level and pressure 8 16 12 2002 4 2 4 3 4 4 The MCD 111 STERYLEX 2000 Microprocessor Controller User s Manual Alarms Configuring reports and alarms This function is described in detail in chapter Protection and Emergency States Set Clock Setting of Controller date and time Tests e digital inputs Enables to switch on and off individual inputs manually Using the lt mode gt key we may have input number or name displayed e outputs Enables to switch on and off individual outputs manually ATTENTION Manual operation mode permits to switch on any output bypassing protections Using the lt mode gt key we may have input number or name displayed e analogue inputs In order to preview values measured by individual sensing elements use the lt lt gt and lt gt gt keys e keyboard Pressing any key will return its own code 4 5 Calibration In order to carry out calibration press the MENU key then move the cursor to the service mode and accept with the ENTER key Next using the cursor go to the calibratio
7. essscnaes 6 3 0 REPORTS care te Peretti Ee eta Ade dt ae A OE thet da en Malet do 6 3 6 SERVICE asada 2 at eR ah BA ee de at O a o tt N act a Eas 6 A SERVICE MENU FUNCTIONS saa ao ao dodac 6 4 1 CONFIGURATION a o iad Meee 6 AZ ATARMS ores NN 9 SO A A A A Fe Ds PAD E A 9 A A TESTS ee A Pe 9 AO CALIBRATION a E DO E E E NS IO NO 9 ZOJNINALISATIO att ABE kat dd dedo lt tds Bhatt ds 10 4 7 PROGRAM PARA METERS il EEA 10 4 0 CODE CHANGE wz OE E Sigel beacon tee E APA teeta adie EDI OCZ 11 4 O CLEARRECORD ca a Ai A E GRO INO ARENY OPOLA 11 5 TEMPERATURE MEASUREMENT scccssscsssscssssssssscsssccsssscsssccsssscsscssssscssscessssesssssssssessesesssscsesssssscssesssess 11 6 SAFETY CODE TPR O O TA 11 6 1 ENTERINGA CODE con 11 6 2 SAFETY CODE CHANGE Sui didas 12 6 3 CODE DEACTIVATION Santa a a a added EE ON ADANIE 12 7 PROTECTION AND EMERGENCY STATES oooonnccnnonooncccnnonionaconnonoonnconnonoonnoonnonononoonnocoonnconnocooonconnocosonconnoconos 12 Lal ALARM CANCELLATION a A a E A ie Bet Boe tc 12 7 2 ALARM CONFIGURATION EEEE 12 TO REPORTS ata R ect td Ed A ORA a W ie recae bd la a 12 8 SPECIFICATION OF INPUTS AND OUTPUTS scccscsssssscesscesscssccssccssesscscecsessssssscesssesseesseessesseesaceeseenses 13 MiCSTER 2 16 12 2002 The MCD 111 STERYLEX 2000 Microprocessor Controller User s Manual 1 Characteristic Features of the Unit The MCD 111 Controller has been designed for the purp
8. g important when the sterilisation process is carried out according to the tl t2 t3 T formula important when the sterilisation process is carried out on the basis of temperature inside the tin and the FO sterilisation value measurement Due to considerable process nonlinearity the FO end value cannot be directly controlled As a result a Fp value has been introduced In order to obtain the required FO end value switch the main sterilisation phase to the cooling phase as soon as advisable Fp value has been reached The Fp switching sterilisation value is an experimental value of the FO coefficient Due to repeatability of the sterilisation process this somewhat primitive adjustment method works well in practice Depending on tin type the Fp values range from 50 to 80 of the FO value It is possible to program 100 technological programs 4 8 Code Change This function permits to enter a new access code to the service menu detailed description chapter 6 4 9 Clear Record Clearing of recording buffer 5 Temperature Measurement Re circulated water temperature and can temperature values are measured with a Pt100 sensor with accuracy of 0 1 C Temperature readouts ranging beyond 50 200 C are treated as sensor malfunction 6 Safety Codes A six digit safety code is used in order to prevent unauthorised persons from accessing and starting the service menu and modifying configurati
9. gency state are attributed to each of these states In case of occurrence of one of mentioned factors and provided that an alarm attributed to it is active program execution will be interrupted This situation will be announced by ALARM message appearing on the display together with an information on alarm cause and its number Additionally sound signal will be activated Press the alarm cancellation key on the Controller panel in order to turn off the sound signal Program restart will be possible only when alarm cause is eliminated The Controller detects the following emergency states of the equipment lack of permission signal too low re circulated water level during pump operation damage of temperature sensors or pressure pick up burnout of fuse on electro valve power supply lack of pump operation status confirmation power supply failure process stoppage using the EMERGENCY STOP key 7 1 Alarm Cancellation In order to cancel alarm press the alarm cancellation key on the Controller panel This results in switching off of the sound and optical signalling system and cancellation of an alarm message 7 2 Alarm Configuration It is possible to switch off each of the alarm sources individually No 0 and to configure alarm to stop the process No 2 or not to stop the process No 1 warning signal Alarm occurrence may result in recording of a report T or not N In order to configure alarms select the alarms function
10. in the service menu 7 3 Reports Reports are recordings of alarm occurrences stored in chronological order in Controller memory In order to read reports select the reports function in the menu and press the lt enter gt key Using mi lt Ste 12 16 12 2002 The MCD 111 STERYLEX 2000 Microprocessor Controller User s Manual the lt mode gt key it is possible to switch between display of alarm occurrence date and time and its number 8 Specification of Inputs and Outputs The Controller control inputs are adapted for direct current signals of 24V preset in relation to common ground The Controller outputs provide direct voltage of 24V and feature current efficiency of 1A whereas total current of outputs may not exceed 3A In order to use these outputs it is required to connect a controller with 24V direct current power supply inputs 70 water level sensor bottom 71 water level sensor top 72 permission to work 73 control signal confirming circulating pump operation 74 control signal informing about failure of electro valve fuses 75 emergency stop 76 control signal for supply voltage 77 78 GND ground analogue inputs Pt 100 T1 Pt 100 T2 hot water Pt 100 T3 can temperature 4 20 mA pressure pick up 0 1000 kPa outputs 40 steam valve steam supply 41 steam valve condensate draining 42 water valve cooling water supply 43 water valve cooling water draining 44 tank de aer
11. n function and accept with the ENTER key e cold water temp Calibration of cold water temperature Go to cold water temp and press the ENTER key Connect 100Q standard resistor to the Pt100 T1 connector which corresponds with temperature of 0 C As soon as indication stabilises press ENTER Using the gt key set yes when answering question are you sure and again accept with ENTER Then connect 138 50 standard resistor which corresponds with 100 C and adjust that temperature value with the TS 1 potentiometer In order to leave the calibration function press ESC e hot water temp Calibration of circulating water temperature 9 16 12 2002 4 6 The MCD 111 STERYLEX 2000 Microprocessor Controller User s Manual The same procedure as for cold water temp but using the Pt100 T2 connector and the TS 2 potentiometer e tin temp Calibration of tin temperature The same procedure as for cold water temp but using the Pt100 T3 connector and the TS 3 potentiometer e pressure Calibration of temperature inside the autoclave Pressure measurement is carried out with help of a pressure transducer with output signal of 0 4 200 mA Because of measurement range of an employed transducer it is required to declare first the p min value the minimum pressure value at which transducer generates current of 0 4 mA and p max the maximum pressure value at which transducer generates current of 20 mA
12. ng to manual operation mode is possible only when the Controller is currently either in the ready mode or in the STOP mode Activation of manual operation keypad is signalled by appearance of Manual operation message on the Controller display 3 Main Menu Functions 3 1 Program Start and Stop In order to activate a program press the START key or select the program start function in menu As a result program number and its abbreviated name and canned food code will appear on the display Then using the lt gt and lt V gt keys select proper program number and press the lt enter gt key Now the display will show a query to enter pot number After entering the pot number with the lt P gt and lt d gt keys press lt enter gt again Further operation of the unit runs automatically in accordance with preset program parameters Point 4 7 Program parameters describes in detail the procedure how to set the technological program parameters 3 2 Program Selection 3 3 Edition The edit program function is used for the purposes of temporary modification of current program parameters 1f the same program is reselected the result will be restoring of parameters originally preset in this program Prior to using this function select number of a program you intend to edit using the select program function This function may also serve to preview parameters of a selected program Any modifications introduced when u
13. ode in order to use these functions 4 Service Menu Functions In order to enter the service menu select the service function in the main menu and enter a 6 digit code The service menu functions are divided in the following subgroups Configuration Alarms Clock Setting Tests Calibration Initialisation Program Parameters Code Change and Delete Recording It is essential that only trained and qualified technical personnel activate the service menu function It is not necessary to use this function during regular operation of the equipment 4 1 Configuration Functions listed below are available e lt F_01 gt max temp Maximum temperature if this temperature level is exceeded it will not be possible to open steam valves and to continue preheating of re circulated water this regards both manual and automatic mode of operation e lt F_02 gt alarm temp Alarm temperature if this temperature level is exceeded execution of the process will be interrupted and sound and optical signalling system will be activated e lt F_03 gt max pressure Maximum pressure if this pressure level is exceeded it will not be possible to open the compressed air valve and to continue increasing of pressure inside the autoclave this regards both manual and automatic mode of operation 6 16 12 2002 The MCD 111 STERYLEX 2000 Microprocessor Controller User s Manual lt F_04 gt alarm pressure Alarm pressure if thi
14. on parameters of the Controller 6 1 Entering a Code When attempting to activate protected functions of the configuration menu a query to enter the code will be displayed Then using the lt P gt or lt d gt and lt lt gt or lt gt gt keys enter the code value and press the lt enter gt key If entered value is correct proper function will be started otherwise the query will be repeated Mmi lt Ste 11 16 12 2002 The MCD 111 STERYLEX 2000 Microprocessor Controller User s Manual 6 2 Safety Code Change In order to change current code change values of successive code digits using the lt P gt or lt d gt key Use the lt gt and lt gt gt key to move to successive digits The new code value will be memorised by the Controller immediately after leaving the code change mode using the lt esc gt key ATTENTION Be particularly careful when modifying the safety code value Be sure to note or precisely memorise the new code value since if it is forgotten it will be impossible to access the configuration menu 6 3 Code Deactivation It is possible to deactivate safety code check before entering a menu function it protects In order to do so change the code by attributing null value for each of its digits 7 Protection and Emergency States The unit emergency states are controlled while the Controller is in operation Alarms which may be individually activated or deactivated lack of reaction to an emer
15. oses of handling control and regulation of the thermal food preservation process which is carried out in a spray sterilizer The Controller works with Windows 95 98 application for visualisation and registration of the sterilisation process The functional features of the unit are as follows e automatic control of the sterilisation process on the basis of sterilisation coefficient F measurement or according to the t1 t2 t3 T formula e measurement of re circulated water temperature and temperature inside the box with accuracy of 0 1 C e making and collection of process files e database with technological program parameters with option permitting to transmit programs to the Controller e auxiliary equipment control dosing pump for descaling agent auxiliary valve for heat exchanger cleaning e recording of equipment emergency states e developed diagnostic and service functions e reliable data transmission in the RS 485 standard 1 1 Description of Controller Operations The MCD 111 Controller is a control and measurement unit used to program sterilisation pasteurisation process carried out in spray autoclaves In an automatic cycle the Controller executes basic autoclave work algorithm taking into account time passage and temperature and pressure fluctuations All operations are executed automatically Running of the manufacturing process with help of the Controller permits to obtain repeatability of technological parameters in
16. r remaining in workspace of the tank will be forced out through a drain valve at pressure of approximately 100 kPa forced by compressed air After passing of preset time the Controller will close the air valve and open the de aeration valve Pressure drop down to the value of 0 kPa will activate sound and optical signalling system which informs about completion of the process 4 16 12 2002 The MCD 111 STERYLEX 2000 Microprocessor Controller User s Manual 2 Using the Controller 2 1 Message Display In order to make operation of the Controller easier for its user the unit is provided with an alphanumeric display permitting to read out and enter system parameters Moreover the Controller is equipped with large 7 segment displays showing current pressure and temperature values inside the autoclave As soon as the Controller is switched on the display shows the initialisation message and Controller type and program version number 2 2 Using Menu In order to switch from regular display mode to menu press the lt menu gt key Select desired function by pressing the lt lt gt and lt gt gt keys and then press the lt enter gt key Use the lt P gt lt l gt keys in order to change function value or program number In order to return to regular operation mode press the lt esc gt key 2 3 Special Keys and Manual Operation Keys Manual operation keypad is located on the left side of the Controller panel Switchi
17. s pressure level is exceeded execution of the process will be interrupted and sound and optical signalling system will be activated lt F_05 gt number in network Number of device in the RS 485 network lt F_06 gt registration period Period of sampling for visualisation and period for computing the sterilisation coefficient lt F_07 gt pot number Allows specifying whether at program start a query for letter determining canned food batch is to be displayed lt F_08 gt reg T k Temperature controller amplification lt F_09 gt reg T Ti Temperature controller integration time lt F_10 gt reg T Td Temperature controller differentiation time lt F_11 gt reg T T0 Temperature controller sampling time lt F_12 gt reg T hist Dead zone of the temperature controller output lt F_13 gt T Tiov When this temperature value is reached integral value of the controller will be replaced with value defined by the Tov parameter lt F_14 gt T Tov Percent value of integral part of the controller which replaces integral value of the controller used so far after reaching the Tiov temperature lt F_15 gt reg p k Pressure controller amplification lt F_16 gt reg p Ti Pressure controller integration time lt F_17 gt reg p Td Pressure controller differentiation time lt F_18 gt reg p T0 Pressure controller sampling time 16 12 2002 The MCD 111 STE
18. sing this function are not stored in the Controller non volatile memory therefore they will be lost after switching off power 5 16 12 2002 The MCD 111 STERYLEX 2000 Microprocessor Controller User s Manual 3 4 Restart and Program Termination In case of program execution failure due to an emergency situation or program execution stopped by the equipment operator 1t is possible to restart the program from the point where it stopped In order to do so press the START key or select the restart function in the menu An alternative option is to terminate program without possibility to continue it To do this select the terminate program function in the menu 3 5 Reports During operation of the equipment all events alarms affecting correct work of the system are recorded All these events sensor failures power supply failures exceeded allowable parameters etc are stored in Controller memory The reports function enables preview of all emergency cases that occur during operation of the equipment The description of most recent alarm and its number will be displayed after selecting this function in the main menu By using the lt mode gt key it is possible to have date and time of alarm occurrence displayed In order to preview previously recorded alarms use the lt P gt and lt gt keys 3 6 Service Service menu functions are used for the purposes of configuration calibration and testing of the unit Enter access c
19. ting phase controller parameters will be corrected in order to allow well timed changing to the proper sterilisation pasteurisation phase lack of over regulation The proper sterilisation process will commence as soon as preset technological values are reached and the time condition is met At this stage the Controller maintains proper temperature and pressure in specified time Cooling procedure will be initiated as soon as preset sterilisation pasteurisation time has passed or if proper sterilisation coefficient value has been reached The cooling phase is divided in three periods During the first one pressure is being increased to the value of 20 kPa above the proper sterilisation pressure value If sterilisation pasteurisation temperature exceeds 100 C the first cooling period lasts no less than 1 3 of assumed total cooling time After this time if cooling water temperature still exceeds 90 C the period in question will be extended at stable pressure The second cooling period is preceded with pressure value decrease by 1 3 in relation to pressure value in the first period and ends with further reduction down to 100 kPa In the third period cooling process lasts until preset end temperature value is reached and the time condition is met If cooling water does not reach the process end temperature even though preset time has passed cooling period will be extended until this condition is met As soon as cooling phase is completed wate
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