AB Control System

for Sterilizers
THAMY Software

Technical
Training
By Asaraf
2/12/2019 Created by Marchel Nir
Maimon 1
System Components

 The main couple of components of the system are the following:

1. Controller - Controlling the sterilizing process of the autoclave.
2. Touch Screen - Providing user interface for the autoclave
operator.
3. Electrical PLC Box

 The Secondary components of the system are the following:

1. Printer – Providing the process information and data of the cycle
by Numeric or Graphic formation.
2. Ethernet Switch – Enable multiple Ethernet cable connection
ports for LAN network communication, up to 5 ports.
3. Barcode – Providing Barcode’s scanning pre cycle start, up to 20
scan’s (items).
4. Independent recorder.
5. SCADA PC – View and control the Autoclave remotely and
establishing cycle reports, up to 16 machines.
2
System Capabilities

1. Enhance PLC - Allen Bradley, MicroLogix1400.

2. Touch screen Interface 5.6”, 7” and 10”.
3. Communications available on board:
 LAN 10/100 Mbps EtherNet/IP
 2 Serial RS-232 ports.
4. Printer connected for online data processing in serial comm.
 Thermal printer (Seiko DPU30, DPU414 graphic)
 Dot Impact printer (Citizen CBM920, IDP3550 2 color).
5. External flash memory for backup the program code for
controller.
6. Supporting Multilanguage
7. Auto Sleep and Start mode options.
8. Calibrating the Analog sensors
9. Up to 22 programs available.
 11 factory validated programs (Wrapped, Unwrapped,
Liquids…).
 7 custom setting programs (Generic 1-7).
 2 test programs (B&D test, Leak test).
3
10.Flexibility and large program parameters setting per cycle.
 Up to 2 sets of pulses – pre-vacuum and post-vacuum.
 Up to 2 sets of temperature staying during heating.
 Heat step – Rating the steam pressure pre sterilization.
 Setting the operation rate on Vacuum, Cooling and Exhaust.
 Dry air on/off.
 Enable/Disable a program.
 F0 Temp.
 Selecting the units display: [°F <-> °C] , [kPa <-> PSI/iHg].
 Printing rates.
 Screen saver time.
11.Barcode (optional)- up to 20 scans.
12.Supporting up to 11 users with up to 5 different levels.
13.Supporting historical Data/Events viewer – up to 2 days.
14.Backup cycles data on external memory card (optional).
15.Trends display and technician In/Out test.

4
 Field
Touch Printer Wiring
Screen
RS232
Main Controller
PLC – ML1400 DO RT AI
D

Touch
Screen
SW
Barcode RS232
Reader Ethernet

Independent Recorder
Printer
Controll
PLC –erML1100

Printer
PC / SCADA

Figure 3 – Communication & 5

Wiring
 Left Side Panel

Male

200 mm
25
FAN

Female
Connector
2 x 32 PIN
-24V (B32)
-24V
7

-24V
TB2
2

+24V Panels
1

+24V Field I/O

+24VDC
24VDC Power Supply

0(B1) / 1(B2)
2(B3) / 3(B4)
TB4
DI

Slot 0

4(B5) / 5(B6)
6(B7) / 7(B8)
8(B9) / 9(B10)

Switch
10/100
PLC
(Slot 0)
8

+24VDC
0(A1) / 1(A2)
PS

2(A3) / 3(A4)
12 VDC

TB5

Slot 0

4(A5) / 5(A6)
6(A7) / 7(A8)
8(A9) / 9(A10)
+24VDC
DO

0(A11) / 1(A12)
2(A13) / 3(A14)
4(A15) / 5(A16)
6(A17) / 7(A18)
TB6

Slot 1

8(A19) / 9(A20)
9
L

10(A21) / 11(A22)
Field
Field

CB2 C4

12(A23) / 13(A24)
14(A25) / 15(A26)
CB1
9
L

T
PLC
CBC2

0e (B11)
0s (B12)
0r (B13)
1e (B14)
1s (B15)
1r (B16)
TB7

2e (B17)
Slot 2

2
RTD

DO

2s (B18)
(Slot 1)

2r (B19)
3e (B20)
1 L1

10

2 T2

3s (B21)
0

3r (B22)
3 L3

4 T4
PKZM
1

+24VDC (B30)
3

0 (B23)
RTD
(Slot 2)
5 L5

6 T6

1 (B24)
TB8

Slot 3

2 (B25)
3 (B26)
2
1

AI

+24VDC (B31)
4
3

0 (B27)
L1 L3

1 (B28)
TB9
6
5

Slot 0

2
DILM

4
AI

3 (B29)
14

(Slot 3)
4-20mA
L5 NO

11

T2 T4 T6 NO A2
13 A1

TB10
G N
Suppressor
From Surge

TB1
Line Feed

G G N N L3 L2 L1

TB11
Surge
Suppresor
0
1

12

380 mm
380 mm

Back door
Front door

Main Switch

600 mm 600 mm
6
7
8
9
10
Controller Overview

 The Controller module is the software program that runs the

Programmable Logic Controller (PLC) during the autoclave
operation. This software module was programmed with the
“RSLogix 500” software application, which was produced and
supplied by the manufacturer of the controller hardware,
“Rockwell Automation Technologies Inc.” (http://www.ab.com/).
Specification for AB ML1400 1766-
L32BWAA :
1. 20 Digital Inputs (24V DC)
2. 4 Analog Inputs (0-10V DC)
3. 12 Digital Outputs (AC/DC relay)
4. 2 Analog Outputs (0-10V DC)
5. Ethernet, RS-232/RS-485 ports
6. LCD display keypad
7. Up to 7 expansion I/O modules

11
 1. Comm port 2 - 9-pin D-Shell RS-232C
connector
2. Memory module
3. User 24V
4. Input terminal block
5. LCD Display Keypad
6. Battery compartment
7. 1762 expansion bus connector
8. Battery connector
9. Output terminal block
10.LCD Screen
11.Controller status
12.Comm port 1 – Ethernet RJ45 connector
13.Comm port 0 - 8-pin mini DIN RS-
232C/RS-485 connector

12
The expansion I/O module is attached to the controller or another
I/O
module by means of a flat ribbon cable after mounting, as shown
below.
The expansion modules:

1. Digital Outputs - 1762-OW1

16 channels AC/DC relay
2. Analog Inputs - 1762-IR4
4 channels RTD/Resistance
3. Analog Inputs – 1762-IF4
4 channels Voltage/Current

13
Touch Screen Overview

 The Touch Screen User Interface module is the software that

provides a Main-Machine Interface (MMI) to the touch screen for
operating the sterilizing machine. This software module was
programmed with the “Easy Builder 8000” software application,
which was produced and supplied by the manufacturer of the
touch screen hardware, “Weintek Labs Inc.”
(http://www.weintek.com/). Specification for Weintek MT8070iH:
1. 7” 800x480 TFT LCD
2. LED Back Light
3. Built-in flash memory and RTC
4. Power Isolator inside
5. SD Card slot
6. Ethernet, RS-232/RS-485 2w/4w
ports
7. USB 1.1 host and USB 2.0 client

14
15
a. DIP SW & Reset button
b. Fuse
c. Power connector
d. VESA 75mm screw holes
e. Audio
f. SD card slot
g. Com1 RS485, Com3 RS485,
Com3 RS232
h. Com1 RS232, Com2 RS232
i. Ethernet port (RJ-45)
j. USB Host port
k. USB Client port

16
 Male
A
1
-24V 2
-24V 3
1 4
2 5
3 6
4 7
5 8
6 9
7 10
8 11
9 12
10 13
11 14
12 15
13 16
14 17
15 18
16 19
17 20
18 21
A

19 22
20 23
21 24
B

22 25
23 26
24 27
25 28
26 29
27 30
28 31
29 32
30 25
31 26
32 27
25 28
26 29
27 30
28 31
29 32
30 -24V
31 -24V
32 -24V
-24V

40 / 41
43 / 44
Off

Relay
Delay

Door2

SI 3-2

45 / 46
47 / 48
49 / 50
Off

Relay
Delay

Door1

SI 3-1
B

Female

17
18
19
 QS OL KM
TB1
L1 T2 L1 T2 L1 T2
L1

L3 T4 L3 T4 L3 T4
L2

L5 T6 L5 T6 L5 T6
L3
PKZM0-xx DILMxx-10
L7 T8
N
P3 - xxx
GND A1
K
A2

A30 TB2
-24V

To Surge
Suppressor

M
3~
Vacuum
Pump

20
 Connector
JB B TB4

B31 B31 FU 2A

OV1
Connector

OV0
PIT-001 B29 B29 3 Air Detect

IV3
+ - TB5 A JB
500Ω

ANA
com
2

IV2

OUT
500Ω

11
TIT-002 B28 B28 1 Filter

IV1
+ -
500Ω

OUT
10
B27 B27 0 Drain

IV0
TIT-001
+ -
Air Detect Water

OUT
500Ω 9 A10 A10 SV-018 1

ANA
com

9
2
Air Detect Steam

OUT
8 A9 A9 SV-099 1

IN19

8
2

VAC
DC6
IN18
Water to Ejector

OUT
7 A8 A8 SV-012 1

IN17

7
2

OUT
Filter Drain 6 A7 A7 SV-072 1

IN16

6
2

VAC
DC5
IN15

OUT
Slow Exhaust 5 A6 A6 SV-074 1

IN14

5
2

OUT
Fast Exhaust 4 A5 A5 SV-073 1

IN13

4
2

VAC
DC4
IN12

OUT
Vacuum 3 A4 A4 SV-075 1

3
com
2

3
LSL-002

VAC
DC3
IN11
A30

OUT
Vacuum Pump/Ejector 2 A3 A3 SV-015 1

IN10

2
2

VAC
DC2
XR-001 A30
PD-002 B10 B10 9 Foot Pedal 2 -24V K

IN9
Steam to Jacket

OUT
1 A2 A2 SV-091 1
B9 B9 8 Foot Pedal 1
IN8

1
PD-001 2

VAC
DC1
com
2

Outputs
LS-001 LS-004

OUT
Steam to Chamber 0 A1 A1 SV-093 1
ES-001 ES-002 B8 B8 7 Emergency Stop
IN7

0
2
50 51

VAC
DC0
LS-006 B7 B7 6 Door 2 Open
IN6

L2/N
VAC
5 (-)
LS-004 B6 B6 Door 2 Close
IN5

PS-004 B5 B5 4 Air Supply

IN4

SI 1
FU 2A A28 A28

VAC
L1
com
1

B4 B4 3 Steam Supply
IN3

PS-005

PS-003 B3 B3 2 Water Supply

IN2

B2 B2 1 Door 1 Open
IN1

LS-003

B1 B1 0 Door 1 Close
IN0

LS-001
PLC
com 0

FU 2A
(-)
(Slot 0)
24V
(+)
DC OUT

+24V
24V
(-)

21
 TB7 Connector B JB

JB Connector B TB7 0e B11 B11

Red
exc0
B17 B17 2e
Red TI-001
exc2
0s B12 B12
TI-003 Red
sns0 Condense
B18 B18 2s
Red
Chamber sns2
White 0r B13 B13
rtn0
B19 B19 2r
White rtn2

nc

nc

nc

RTD

(Slot 2)

nc

nc

nc
B20 B20 3e
Red
exc3
TI-004 Red
1e B14 B14
exc1
B21 B21 3s
Red TI-002
BH sns3
1s B15 B15
sns1 Red
3r
Condense
B22 B22 White
rtn3
1r B16 B16
rtn1 White

22
 TB8 Connector B JB

Pressure Chamber 0 B23 B23

In 0 + - Chamber
+ Pres 1
TB2
-24V In 0 -
Pressure Jacket 1 B24 B24
Jacket
In 1 + - + Pres 2
In 1 -
2 B25 B25
Door Pressure 1 Gasket Door 1
In 2 + - + Pres 3
In 2 -
3 B26 B26
Door Pressure 2 Gasket Door 2
In 3 + - + Pres 4
In 3 -
TB8 FU Com (+) B30 B30

+24V 1A
COM

AI
COM
(Slot 3)

23
 Buzzer
BZ-002
AB Connector A TB6
VDC1 TB6 Connector A AB
BZ-001 0
A11 A11 Buzzer
Out 0 SV-039-1
Pres. Sw Door 1 Close 1 A12 A2 A47 A43
2
Gasket 1 SV-038-1 Out 1 16
15 1 3
A40 A13 A13 2 Door 1 Open SI 3 (1) SI 3 (1)
A45 1
2
Out 2
PS-001 2
SI 2 Door 1 Lock Seal 3 A14 A14
2 SV-034-1
SV-053-1 18 Out 3
SI 3 (1) A15 4 1
1 A15 Door 1 Unlock Unseal Pres. Sw
Out 4 Gasket 2
2
Door 2 Open 5 A16 A16 A40
Out 5 2 A46
SV-039-2 2
A48 A17 6 1 PS-002
A44 1 A17 Door 2 Close SI 2
3 15
Out 6 18 SV-038-2
2 16
SI 3 (2)
SI 3 (2) SI 3 (2)

A18 A18 7 Door 2 Lock Seal

SV-034-2 1
Out 7
2
DO

(Slot 1)

VDC2

SV-053-2
A40 A19 A19 8 Door 2 Unlock Unseal
1
2 2
Out 8
SI 2 Atmospheric Air 9 A20 A20
2 SV-043
LVS-003 Out 9
A?? A21 10 1
SV-011/068 1 A21 Cool Water / Drain Jacket
Out 10
2 11 A22
Cooling Vacuum A22 2 SV-031
Out 11
SV-098/066
A23 A23 12
Bio Filter 1
1
Out 12
2 13 A24
Bio Vacuum A24 SV-076/096
Out 13 2
A25 A25 14 Drain 1
SV-012 1
2
Out 14
Main Exhaust 15 A26 A26 SV-070
2
Out 15
(-) 1

(-)

TB5 TB6 FU

5A

24
Safety Interlock 2
(SI 2)
RT112 Eliwell GICAR
JB JB

A40 2 (-)
1 2 1 2 1
A32

Connector
(A32)

TB2
-24V

25
26
Eliwell

IC912

1 2 3 6 7 10 11 12

Out Supply Pt100

AC/DC Sensor

27
GICAR Chamber
A32 Water Level
RT112 Relay

1 2
Sm

GICAR DRLH

SM R L N

Electrode high
(water )

VAC
Electrode
Reference

28
Safety Interlock 3
(SI 3)
n.o. 2
c

n.c. 3

n.o.
c
n.c.

n.o.
1 c AB
n.c. Off Delay
Relay
From PLC Close Door
Output (+24V)

A12
(A17)

A2 15

E, 2min
(-) A1 B1 16 18

A41 A13
2 (A42) (A16)
Red
White 1
Black 1 1 Open
2 Door
3 A43 2 A47
(A44) Close (A48) (-)
Door Switch
Door

Use SI 3 for Automatic sliding doors only.

29
Safety Interlock 1
(SI 1)

JB

ES1 ES2
A28 A27
B32 B8

A28

A27
B8
(-)

Connector A

2
TB2 TB4 TB5 TB2
PLC Box
IN7 +24V

30
Feed from Main Switch
See drawing - ES1P03-0002-0002

L1
Surge
N
Suppressor
G Recorder Safety Interlock 1
PIT-005
TB10 (SI 1)

TI-002 Pressure
chamber JB

Pt100
CB1 condense ES1 ES2
A28 A27
L

From JB (B30) +24VDC

T B32 B8
L PLC N

From (B32) -24VDC

2A
R=250Ω Start/Stop
Relay (CR3)

A28

A27
Yellow

B8
(-)
NO Connector A
CB2

Red

Red
L T GICAR
L N 2
4A DRLH 13 12 11 31 32 11 21 TB2 TB4 TB5 TB2
PLC Box
IN7 +24V
Recorder
FUJI ~ VAC

L Eliwell N Safety Interlock 2

(SI 2)
RT112 Eliwell GICAR
Eliwell JB JB

A40 2 (-)
1 2 1 2 1
IC912 A32

Power Supply Connector

L N 1 2 3 6 7 10 11 12
5/12 VDC (A32)

+ - TB2
-24V

Printer Safety Interlock 3

(SI 3)
Out Supply Pt100 n.o. 2
c
AC/DC Sensor
n.c. 3

GICAR n.o.
Power Supply Chamber c
L 24 VDC N A32
Water Level
n.c.
RT112 Relay
+- +- n.o.
1 c AB
TB2 n.c. Off Delay
Relay
From PLC Close Door
Output (+24V)
1 2
Sm
Connector A Connector A A12
GICAR DRLH (A17)
JB JB
SI1 A2 15
A27 A27 A28 (-) A32
+ Panel View 1 - SM R L N E, 2min
(-) A1 B1 16 18
Electrode high
(water )
A41 A13
2 (A42) (A16)
Red
White 1
+ Panel View 2 - Black 1 1 Open
2 Door
3 A43 2 A47
VAC (A44) Close (A48) (-)
Door Switch
Electrode Door
Reference

Use SI 3 for Automatic sliding doors only.

Control Electrical Panel

Cascade Diagram ES1P05-0001

31
 PIT-005

TI-002 Pressure
chamber
Pt100
condense

From JB (B30) +24VDC

From (B32) -24VDC

R=250Ω Start/Stop
Relay (CR3)
Yellow

NO
Red

Red

13 12 11 31 32 11 21

Recorder
FUJI ~ VAC

32
 IP Address Setting

<OK
>
<OK
>

<OK <OK
> >
<OK
See IP Set IP >
status Address

<OK <OK
> >
<OK
>

<ES
<OK C>
>

33
Memory Module – Load from MM

<OK <OK
> >

<OK <OK
> >

<OK
<OK >
>

<ES
C>

34
Memory Module – Store to MM

<OK <OK
> >

<OK <OK
> >

<OK <OK
> >

<ES
C>
35
LCD Setup – Back Light

<OK <OK
> >

<OK <OK
> >

<ES
C>

36
System Setting Bar

37
System Setting

Setting Bar

Network Security

38
More System Setting
Time/Date History Firmware Setting

Flash Memory Card VNC Server

39
Download Project to Panel via USB Device

Extrac Save Plug

t in
Zip File
name USB
file Touch
Device
Screen

+ usbdisk
+ device-0
+…………
+…………
+ File
name
+…………
+…………
Highlight only
No sub
selection

40
41