Consolidated Mark II User manual

The MKII Controller Operator’s Guide
1

Note: Always have this machine’s model
and serial number (printed on the first page
of this document) ready when calling
Consolidated for service or parts.
WARNING
If this sterilizer’s chamber is constructed of Stainless
Steel, NEVER use CHLORIDE based cleaners to
clean this sterilizer. NEVER sterilize items containing
CHLORIDES or producing CHLORIDE GASES in
this sterilizer. CHLORIDES have proven to damage
the Stainless Steel material causing cracks and pin
holes, which will lead to steam leaks.
The MKII Controller Operator’s Guide
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Operating Manual
"Mark II"
Solid-State Digital Automatic
Controlled Sterilizers
The MKII Controller Operator’s Guide
3
Rev. 070129
PLEASE READ CAREFULLY BEFORE
ATTEMPTING TO OPERATE YOUR STERILIZER.
Copyright:
Consolidated Stills and Sterilizers
76 Ashford Street
P.O. Box 297
Boston, MA 02134-0003 U.S.A.
Tel: [phone] Fax: [phone]

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TABLE OF CONTENTS
1. INTRODUCTION 6
1.1 Safety Instructions 7
1.1.1 Aborting a Cycle 7
1.1.2 Starting a Cycle 7
1.1.3 Preparing the Load 8
1.1.4 Sterilizing Fluids 8
2. OVERVIEW OF THE MARK II CONTROLLER 9
2.1 Description 9
2.2 Chamber Pressure Gauge 10
2.3 Circuit Breaker 10
2.4 Cycle Selector Switch 10
2.5 Jacket Reset Button and Light 10
2.6 MKII Controller 10
2.7 Chart Recorder 10
3. CYCLE SELECTOR SWITCH OPERATION 11
3.1 ON/OFF 11
3.2 FAST 11
3.3 FLUID 12
3.4 DRY 13
4. MKII CONTROLLER 14

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4.1 Setting Sterilization Time 15
4.2 Setting Dry Time 15
4.3 Low Temp Cycle 16
5. CHART RECORDER & CONTROLLER 19
5.1 Setting Sterilization Temperature 20
5.2 Changing Chart Recorder Paper 20
6. OPERATING INSTRUCTIONS TUTORIAL 21
6.1 Direct Steam Sterilizers 21
6.2 Generator-Equipped Sterilizers 23
6.2.1 Sterilizers equipped with Automatic Generator Blow-down 28
6.3 Sterilizers with Automatic Jacket Blow-down 28
6.4 Double Door Sterilizers 29
6.4.1 Double Door Sterilizers with Remote Start 29
6.5 Sterilizers with Post-Vac System 30
7. LOAD PREPARATION 31

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1. Introduction
The fully automatic Consolidated SSR and SR series of sterilizers are intended for use by
facilities to sterilize heat and moisture stable materials by means of pressurized steam.
These sterilizers are available in several different chamber sizes.
The Mark II control system continuously monitors and visually displays the relevant
temperature and pressures in the sterilizer. It also automatically initiates and controls
each phase of the sterilization cycle -- condition, sterilize, and exhaust -- for greater
assurance of sterilization.
Our sterilizers can either be supplied for connection to direct building steam supply of
50-80 PSI of pressure, or come equipped with an integral, electrically heated steam
generator. The Mark II controls are identical for both types.
Consolidated sterilizers have been on the market since 1948 and enjoy an excellent
reputation for quality and reliability. One of our design goals is to use off-the-shelf
components on our machines whenever possible to minimize down time and service costs
to our valued customers. Most of the solenoids, valves, and steam-traps used in our
machines are available from your local service representative.
Many optional items, such as automatic jacket and generator blow-down are available
with the Mark II control system. Specialized sterilization cycles, such as low-
temperature sterilization are also available.

1.1 Safety Instructions
The following safety instructions appear in this manual. Please read them carefully
before operating the sterilizer.
1.1.1 Aborting a Cycle
WARNING: RISK OF NON-
STERILE DEVICE
Please note that if a cycle is aborted prior to successful termination, it must
be considered incomplete and the load must be reprocessed (unwrapped
goods or liquids) or repacked and reprocessed (wrapped goods).
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To abort a cycle in progress, press the red POWER key on the keypad assembly.
This will shut off power to the unit. You will then need to open the green–handled
manual exhaust valve (labeled Manual Steam Exhaust Valve) visible by removing
the access panel below the chamber door. Wait for the pressure inside the chamber
to reach atmosphere before carefully opening the door.
1.1.2 Starting a Cycle
WARNING: BURN HAZARD
The operator MUST wear protective clothing including face shield, thermal gloves,
and proper lab attire, when attempting to load and unload the chamber materials.
Steam released from the sterilizer chamber can cause serious burns. Stand away
while opening the door.
If water leaks from the front of the sterilizer, DO NOT open the door. Contact
service personnel.
!
!

To start a cycle, make sure the door is hand-tight. Press the appropriate selector switch
for the type of cycle you are running (Fast, Dry, or Fluids), then press the red power
button on the selector switch to start the cycle. See section 6 for a complete tutorial
before you start operating the machine.
1.1.3 Preparing the Load
WARNING: RISK OF
INFECTION
Please note that airborne microbial and particulate contamination is likely to
be high in the decontamination area of the sterile processing department.
Users MUST wear protective clothing and equipment when preparing goods
for sterilization or when in the decontamination area.
!
Please see section 7.2 on load preparation before you start operating the machine.
1.1.4 Sterilizing Fluids
WARNING: INJURY
HAZARD
If the wrong cycle is selected to sterilize liquids, the containers may burst
or crack during the processing.
After completion of a FLUIDS cycle, take care that you do not agitate the
fluids during removal from the chamber. Otherwise the containers may
burst or crack.
!
WARNING!
Sterilized liquids are not intended for direct patient contact.
!
Please see Section 3.3 on Sterilizing Fluids.
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2. Overview of the Mark II Controller
The Mark II is a simple, easy-to-operate sterilizer control system. It allows selection of
sterilizer cycles, setting of temperature, and times for Sterilization and Dry. It displays
status of the machine in sterilize or exhaust modes, executes selected cycles, and prints a
chart of sterilizer temperature vs. time. Figure 2.1 shows a typical Mark II controller
with a chart recorder.
ON
OFF FAST FLUID DRY
CIRCUIT
BREAKER
Chart Recorder
Chamber Pressure Gauge Cycle Selector Switch
Circuit Breaker MKII Controller
RESET
JACKET STEAM
Jacket Reset Button
Jacket Light
Figure 2.1 The Mark II Controller & Chart Recorder
2.1 Description
The Mark II controller was designed with simplicity of operation in mind. The controller
allows setting of sterilization time and dry time (for a Dry cycle only). LEDs on the
controller show when the machine is in the sterilize mode and when it is in the exhaust
mode. A selector switch (see Figure 2.1) allows user to select one of three types of
cycles: Fast, Fluid, & Dry. A pressure gauge shows the current steam pressure inside the
chamber of the sterilizer. A chart recorder records a graph of time vs. temperature during
the cycle. For Low-Temp equipped sterilizers, please see section 4.3.
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2.2 Chamber Pressure Gauge
The chamber pressure gauge shows the steam pressure in the chamber at all times. Make
sure this gauge registers zero before you attempt to open the door.
2.3 Circuit Breaker
The circuit breaker’s purpose is to protect the electronics. If the circuit breaker cuts off
the power to the sterilizer, a qualified technician needs to troubleshoot the source of the
problem before resetting it.
2.4 Cycle Selector Switch
You can choose the type of cycle you want to run with the cycle selector switch. The
cycle selector switch also acts as the ON/OFF button for the sterilizer. See section 3 on
Selector Switch operation.
2.5 Jacket Reset Button and Light
When the green Jacket Light (see Figure 2.1) comes on, you need to press the Jacket
Reset Button and wait for the jacket pressure to build up before you can start a new cycle.
2.6 MKII Controller
You can set the sterilizer and exhaust (in case of a Dry cycle) time and view the
remaining time on the MKII controller. See section 4 for more information.
2.7 Chart Recorder
The chart recorder offers a chart of time vs. temperature for your sterilization cycle. You
can also set the temperature for your sterilization cycle on the chart recorder. See section
5 for more information.
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3. Cycle Selector Switch Operation
The cycle selector switch is used to select the type of cycle to run and to start a cycle.
The cycle selector switch is located on the front of the sterilizer near the controller (See
Figure 2.1). The cycle selector switch is depicted in Figure 3.1 below. For Low-Temp
equipped sterilizers, please see section 4.3.
ON
OFF FAST FLUID DRY
Figure 3.1 Cycle Selector Switch
3.1 ON/OFF
With the ON/OFF switch in the OFF position, select the type of cycle you want to run by
pressing the FAST, FLUID, or DRY button as in Figure 3.1 above. After you have
chosen which type of cycle you want to run, depress the ON/OFF switch to start a cycle.
3.2 FAST
Choose a FAST cycle if you are sterilizing instruments or other items that do not require
a drying phase or are not liquids. At the conclusion of the sterilization phase of the
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FAST cycle, the steam pressure in the chamber will be reduced to atmosphere as quickly
as possible and the end-of-cycle buzzer will sound.
3.3 FLUID
WARNING!
Sterilized liquids are not intended for direct patient contact.
!
Choose a FLUID cycle if you are sterilizing liquids or media. At the conclusion of the
sterilization phase of the FLUID cycle, the steam pressure in the chamber will be reduced
to atmosphere very slowly in order to minimize boil-over. When the chamber pressure
reaches atmosphere, the end-of-cycle buzzer will sound.
Liquid Quantity
(mL) Time Setting (Minutes)
75 25
250 30
500 40
1000 45
1500 50
2000 55
Minimum Recommended Exposure Times at 250°F (121°C) for
Liquids (Solutions, Water, Media, etc.)
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The MKII Controller Operator’s Guide
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Note:
1. These are suggested minimum exposure times. Additional time may be required
if flasks are placed in plastic container.
2. Utilize smaller volumes whenever possible. Larger volumes of liquid will take
longer to come up to temperature.
WARNING: INJURY
HAZARD
If the wrong cycle is selected to sterilize liquids, the containers may burst
or crack during the processing.
After completion of a FLUIDS cycle, take care that you do not agitate the
fluids during removal from the chamber. Otherwise the containers may
burst or crack.
!
3.4 DRY
Choose a DRY cycle if you are sterilizing packs, instruments, or other items that require
a drying phase. At the conclusion of the sterilization phase of the DRY cycle, the steam
pressure in the chamber will be reduced to atmosphere as quickly as possible, then the
end-of-cycle buzzer will sound after the required number of minutes in DRY time.

4. MKII Controller
STERILIZE (MINUTES) DRY (MINUTES)
STERILIZING EXHAUSTING
CONSOLIDATED
MK II CONTROLLER
030 20
Remaining
Time
Display
Dry Time
Setting
Thumbwheels
Exhaust
Phase
Indicator
Sterilize
Phase
Indicator
Sterilize
Time
Setting
Thumbwheels
DIGITS REPRESENT MINUTES
Figure 4.1
MK II Controller Face Plate
The MK II controller allows you to set the Sterilize and Dry times (if necessary). It uses
two LED lights to indicate if the cycle is in the Sterilize or Exhaust phase. Using the
thumbwheels on the top of the controller, set your Sterilize and Dry times in minutes.
Then select FAST, DRY, or FLUID exhaust phases using the selector switches (See
section 3). Once the sterilizer reaches the set sterilization temperature, the sterilize light
will come on and stay on for the duration of the set Sterilize Time period. If the
temperature inside the chamber goes below your Sterilization Temperature set point, the
controller will re-start the sterilization phase. After a successful sterilization phase, the
Exhaust indicator light will come on and stay on for the duration of the Exhaust phase of
the cycle. At the end of the Exhaust phase, the buzzer will sound. You may now open
the sterilizer door after checking the pressure gauge to make sure that the pressure has
reached zero atmospheres inside the chamber. For Low-Temp equipped sterilizers,
please see section 4.3.
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4.1 Setting Sterilization Time
Turn the Sterilize Time Setting thumbwheels (see Figure 4.1) to the desired number of
minutes for your sterilization phase.
Note that if the selected cycle on the cycle selector switch (see Figure 3.1) is FAST or
FLUID, the controller will ignore the time set on the Dry Time Setting thumbwheels (see
Figure 4.1).
4.2 Setting Dry Time
Turn the Dry Time Setting thumbwheels (see Figure 4.1) to the desired number of
minutes for the Dry phase.
Note that the Dry Time is only in effect if the selected cycle on the cycle selector switch
(see Figure 3.1) is DRY. At the end of the exhaust phase of the cycle, the controller will
wait this many minutes before it sounds the end-of cycle buzzer.
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4.3 Low Temp Cycle
This section applies to machines equipped with LOW-TEMP STERILIZATION CYCLE
ONLY.
If your machine is equipped with Low-Temp cycle capability, to start a cycle, you should
make sure that the Low-Temp selector switch (Figure 4.2), the Chamber Steam Low-
Temp Control switch (Figure 4.3), and the Jacket Steam Low-Temp Control switch
(Figure 4.4) are all in Low-Temp mode. Make sure that the sterilizer door is sealed and
tightened. Set the chart recorder (Figure 5.1) to a temperature in the range of 172 F to
212 F. Press the red ON/OFF switch (Figure 3.1) to the ON position. You do not need to
depress any of the cycle selector switches. The Low-Temp cycle will commence. After
the end-of-cycle buzzer sounds, make sure the Chamber pressure gauge reads ZERO
before opening the door.
When running a LOW-TEMP cycle, you should pay attention to the following:
1) Make sure you set the chart recorder (see section 5) to a temperature in the range
of 172 F – 212 F.
2) Make sure that you leave sufficient space between the articles in the chamber to
allow circulation of the air-steam mixture throughout the load.
3) During a LOW-TEMP cycle, the chamber is NOT pressurized. You should
always check the chamber pressure gauge before opening the door of the sterilizer
to make sure it registers zero.
4) It is highly recommended that you schedule all LOW-TEMP sterilization at the
beginning of the day when the sterilizer is cold and the jacket has not been
pressurized. This will prevent moisture from entering the chamber, which may
de-stabilize the temperature in the chamber.
WARNING: BURN HAZARD
The operator MUST wear protective clothing including face shield, thermal gloves,
and proper lab attire, when attempting to load and unload the chamber materials.
Steam released from the sterilizer chamber can cause serious burns. Stand away
while opening the door.
If water leaks from the front of the sterilizer, DO NOT open the door. Contact
service personnel.
!
To run a LOW-TEMP cycle, make sure you toggle the selector switch on the MKII
controller to LOW-TEMP. See Figure 4.2 below. The LOW-TEMP light will be on
during the cycle.
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STERILIZE (MINUTES) DRY (MINUTES)
STERILIZING
EXHAUSTING
CONSOLIDATED
MK II L CONTROLLER
030 20
Remaining
Time
Display
Dry Time
Setting
REGULAR vs.
LO-TEMP
Selector Switch
Exhaust
Phase
Indicator
Sterilize
Time
Setting
DIGITS REPRESENT MINUTES
LO-TEMP
REGULAR
LO-TEMP
Indicator Light
Sterilize
Phase
Indicator
Figure 4.2
MK II LOW-TEMP Controller Face Plate
You should also make sure to toggle the Chamber Steam Low-Temp Control switch to
LOW-TEMP. See Figure 4.3 below.
ON
OFF FAST FLUID DRY
CIRCUIT
BREAKER
Chart Recorder
Chamber Pressure Gauge Cycle Selector Switch
Circuit Breaker MKII Controller
RESET
JACKET STEAM
Jacket Reset Button
Jacket Light
LO-TEMP
REGULAR
Figure 4.3
The Low-Temp Mark II Controller & Chart Recorder
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Finally, make sure you toggle the Jacket Steam Low-Temp Control switch to Low-Temp
as depicted below in Figure 4.4.
ON
OFF FAST FLUID DRY
CIRCUIT
BREAKER
RESET
JACKET STEAM
Generator
Switch
LO-TEMP
REGULAR
LO-TEMP
REGULAR
Figure 4.4
Front view of typical Low-Temp equipped sterilizer
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5. Chart Recorder & Controller
Set
Point
Knob
Orange Setting
Pointer
Green
Indicating Pointer
Chart Paper
Stylus
Chart Knob
Chart Paper
Index
Figure 5.1
Chart Recorder/Controller
The chart recorder (see Figure 5.1) records a chart of time vs. sterilization temperature. It
also allows you to set the sterilization temperature.
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WARNING: Damage to the
Chart Recorder
The Chart Recorder/Controller’s Green Indicating Pointer and Orange Set
Pointer (see Figure 5.1) must not be manipulated by hand or any tools in
an attempt to swing them up or down the scale. This can result in serious
damage to the recorder’s linkage. This damage is not covered under your
sterilizer’s warranty.
!
5.1 Setting Sterilization Temperature
Use the set-point knob (see Figure 5.1) to set the sterilization temperature.
5.2 Changing Chart Recorder Paper
WARNING: Damage to the
Chart Recorder
The Chart Recorder/Controller should never operate without chart paper.
This will damage the stylus’ sapphire tip (see Figure 5.1). This damage is
not covered under your sterilizer’s warranty.
!
To remove the old chart, unscrew the chart knob (see Figure 5.1) and swing the chart
knob arm counter-clockwise out of the way. Raise the stylus pen by pressing on the tab
at the uppermost end of the arm. List the old Chart forward off the hub and slide down
and away. Do not release the stylus pen arm. Install the new chart paper. Align the
proper chart time with the chart plate index (see Figure 5.1).
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