Page 1 Operators Handbook D C U 3 - S y s t e m Digital Measurement and Control System for Fermentors BAEDCU3 - Rev. 4.6 - 0504...
Page 3 „DCU-Host Communication“. Both these manuals are available on request. The digital control system DCU3 is one example of Sartorius BBI Systems´ product program of sophis- ticated fermentation and peripheral laboratory equipment. For further information about this device and...
Page 4 Operators Handbook DCU3 – System Introduction BAEDCU3 - Rev. 4.6 - 0504...
Page 5: Table Of Contents
Operators Handbook DCU3 – System Contents Contents Page Introduction Design and Function 1 - 1 Operating Behaviour Switching „off“ and „on“ 2 - 1 Mains Failure 2 - 1 Shut Down Function 2 - 2 Interlocking Functions 2 - 2 Function Selection and Inputs Operating Terminal 3 - 1...
Page 6 Operators Handbook DCU3 – System Contents pH - Control Function Operating as PID - Controller 6 - 11 -Control Methods 6 - 12 6.10 - Cascade Controller with 3 Servo Controllers 6 - 12 6.11 - Cascade Controller with 4 Servo Controllers 6 - 16 6.12 -Gasmix Controller / O...
Page 7 Operators Handbook DCU3 – System Contents Manual Operation for Analog Outputs 9 - 8 Settings of Measurement Ranges 9 - 10 Connection of External Devices 9 - 11 Host Interface 9 - 12 9.10 Peripheral Interface 9 - 14 9.11 Balance Interface 9 - 15 9.12...
Page 8 Operators Handbook DCU3 – System Contents BAEDCU3 - Rev. 4.6 - 0504...
Page 9 ® For the fermentors of the BIOSTAT series the Sartorius BBI Systems GmbH offers a broad range of standard configurations of the DCU3 – system, which consider the features of the individual type of fermentor. However, the extent of functions implemented for a delivered system will always depend on the specifications of the customer, as agreed prior to ordering of the fermentor system.
Page 10: Design And Function
Operators Handbook DCU3 – System 1., Design and Function BAEDCU3 - Rev. 4.6 - 0504 1 - 2...
Page 11: Operating Behaviour
Operators Handbook DCU3 – System 2., Operating Behaviour OPERATING BEHAVIOUR The DCU3 - system stores all parameters which are adjustable by the operator (setpoint, calibration parameters, profiles, etc.) in a battery buffered memory. Hence these parameters are still available when the DCU3 system is switched off and restarted again. For enabling the outputs of the DCU3 - system and of several system functions, which directly act on the fermentor system, 4 categories of switching-off or power failure, respectively, are differentiated: Switching „off“...
Page 12: Shut Down Function
Operators Handbook DCU3 – System 2., Operating Behaviour Shut Down Function The shut down function can be released by : Enabling the „SHUT DOWN“ key on the operating terminal and Enabling the mains switch of the fermentor (located on the supply unit or cabinet). In the shut down state all outputs are switched over to their predefined safe state.
Page 13: Function Selection And Inputs
Operators Handbook DCU3 – System 3., Function Selection and Inputs FUNCTION SELECTION AND INPUTS Operating Terminal The DCU3 - system has an especially developed touch screen terminal for display of all process pa- rameters and for operation of the entire unit. This „touch terminal“ has integrated „touch keys“ where the operator can select the menus and the related subfunctions, enter data and select and switch-over the modes for fermentor operation.
Page 14 Operators Handbook DCU3 – System 3., Function Selection and Inputs Structure of the Touch Screen Display, on the page above shown for the „Main“ menu: 1. line: Status line: Used for hhhh:mm Display and Input of process time Fermentation (etc.) Display of operating state.
Page 15 Operators Handbook DCU3 – System 3., Function Selection and Inputs 3.1.2 Functional Keys of the Working Area For a selected function the lowest line of the working area can have additional touch keys, which are especially assigned to this function and allow for direct access to the corresponding submenus. Example: Operating display of the pO - controller with touch keys: The following touch keys for function selection are available in the working area of the oper-...
Page 16 Operators Handbook DCU3 – System 3., Function Selection and Inputs 3.1.3 Selection of Menus and Entering of Parameters The operation of the DCU3 - system is organized systematically. Related tasks of fermentor operation are combined in functional groups - the „main functions“ listed below. A main function can be directly activated at any time during the running process from any submenu by pressing the corresponding main function touch key at the screen.
Page 17 Operators Handbook DCU3 – System 3., Function Selection and Inputs 3.1.4 „Touch keys“ in the Menu „Main“ After switching on of the system the graphical overview in the menu „Main“ provides a schematic dis- play of the main functional elements of the individual fermentor system, together with the most import process parameters and the „touch keys“...
Page 18 Operators Handbook DCU3 – System 3., Function Selection and Inputs Switching over the main menu dis- plays for 2…4 culture vessels via direct function key CHANGE UNIT: CHANGE UNIT CHANGE UNIT ..BAEDCU3 - Rev. 4.6 - 0504 3 - 6...
Page 19: Inputs
Operators Handbook DCU3 – System 3., Function Selection and Inputs 3.1.5 Direct Function Keys The direct function keys on right hand of the „Touch Terminal“ allow for direct access to the system: SHUT DOWN : Pressingthis key sets all analog and digital outputs into a safe state. An active SHUT DOWN state is indicated by lighting LED in the key.
Page 20 Operators Handbook DCU3 – System 3., Function Selection and Inputs Input of text: Enter the text with a max. number of letters (Range). At wrong inputs delete the entry using the „<-“ key or CANCEL. Confirm the Entry with „Ok“. The system closes the keypad and displays the text.
Page 21: Start-Menü „Main
Operators Handbook DCU3 – System 4., Start-Menü „Main“ START-MENÜ „MAIN“ General Notes The „Main“ menu is displayed after switching on the DCU3 - system. With the new „object-based“ dis- play of entries and the direct selection of submenus and functions for data input and mode selection, the main menu is the control center for operation during a fermentation run.
Page 22 Operators Handbook DCU3 – System 4., Start-Menü „Main“ 4.2.1 Alarms If a process value exceeds its alarm limit or if a device is switched over to an alarm state the backround color of the corresponding symbol changes to red (in this „laser-printed“ manual shown light-grey, see example for the entry of foam measurement).
Page 23: Main Function „Calibration
Operators Handbook DCU3 – System 5., Main Function „Calibration“ MAIN FUNCTION „CALIBRATION“ General Note All calibration functions required for routine operation of the fermentor can be executed using the main function „calibration“. You can select the following functions via the corresponding selection menu: Selection menu „Calibration“: The entries refer to the following functions: –...
Page 24: Ph - Calibration
Operators Handbook DCU3 – System 5., Main Function „Calibration“ pH - Calibration The pH electrode is calibrated by a two-point calibration using liquid buffers. The calibration is done before the electrode is installed in the culture vessel. For details about preparing of the pH-electrode and handling during calibration see the operating information delivered by the manufacturer.
Page 25 Operators Handbook DCU3 – System 5., Main Function „Calibration“ Additional touch keys, tags and entries displayed depending on the selected function: Entry Displayed value or function, required input TMPCO degC Input of temperature for manual temperature compensation BUFFZ Input of pH-value of zero buffer −...
Page 26: Po 2 - Calibration
Operators Handbook DCU3 – System 5., Main Function „Calibration“ - Calibration The pO - electrode is calibrated in terms of percentage oxygen saturation, „% pO “. The calibration is a two-position calibration. In a fermentor the oxygen-free culture medium is the zero reference and the medium saturated with oxygen is the „100 % pO “...
Page 27: Redox - Calibration
Operators Handbook DCU3 – System 5., Main Function „Calibration“ Redox - Calibration The Redox calibration is in fact a functional check. You will measure a calibration buffer and compare the measured value with the reference indicated on the buffer bottle. If these values are different, the Redox can be entered manually.
Page 28: Calibration Of Turbidimetry Measurement
Operators Handbook DCU3 – System 5., Main Function „Calibration“ Calibration of Turbidimetry Measurement Calibration of the turbimetry measurement probe is a „single-step“ procedure evalulating the „zero de- viation“ of the sensor is. For this the sensor is placed into particle- and bubble-free deinonized water. The system calculates the turbidimetry as the arithmetical mean of the value measured during a de- fined measuring time in terms of „absorption units, AU“.
Page 29 Operators Handbook DCU3 – System 5., Main Function „Calibration“ 5.5.2 Calibration For calibration of the turbidimetry sensor proceed as follows. Start the calibration via „Start Calibration“ Follow the instructions of the calibration menu. 5.5.3 Special Notes If the lamp is switched on, it will be kept in „on“-state when the DCU3 - system is switched off and on again.
Page 30: Totalizer For Pumps And Valves
Operators Handbook DCU3 – System 5., Main Function „Calibration“ Totalizer for Pumps and Valves For monitoring of the corrective agent consumption the dosing times of the pumps or of the dosing valves are totalized and used as process values. The DCU3 - system converts the dosing times into delivered volumes considering the specific flowrates of the pumps or of the dosing valves.
Page 31 Operators Handbook DCU3 – System 5., Main Function „Calibration“ 5.6.2 Calibration of a Pump For calibration allways use tubings of the same type and dimensions as for the delivery of media during the process. Place one end of the tubing into a beaker filled with water and the other end into a measur- ing beaker.
Page 32: Calibration Of A Balance System
Operators Handbook DCU3 – System 5., Main Function „Calibration“ Calibration of a Balance System The fermentor weight (the „vessel content“) can be measured by balance platforms or load cells (i.e. optional accessories). They will be connected to the DCU3 via a strain gauge measuring amplifier. The measurement amplifier is scaled to a gross weight output signal.
Page 33: Flow Calibration
Operators Handbook DCU3 – System 5., Main Function „Calibration“ Flow Calibration The dosing control function of the DCU3 - system operates with a remote balance system, which measures the weight of the substrate. The balance system is connected to the DCU3 - system via a serial interface.
Page 34 Operators Handbook DCU3 – System 5., Main Function „Calibration“ 5.8.2 Special Notes It is recommende to set a cycle interval of 10 minutes. When selecting an interval of 10 or 60 minutes, respectively, the calculation and display of the flowrate starts with the shortest interval and automatically switches over to the next longer one.
Page 35: Main Function „Control Loops
Operators Handbook DCU3 – System 6., Main function „Control Loops“ MAIN FUNCTION „CONTROL LOOPS“ Equipment and Functional Principles All control loops in the DCU3 - system are DDC controllers. They operate either as PID controllers, setpoint controllers or on/off controllers and are adapted to the related control loops. Depending on the actuator their output is either continuous or pulsewidth-modulated (pwm).
Page 36: Selection Of Controller
Operators Handbook DCU3 – System 6., Main function „Control Loops“ Selection of Controller 6.2.1 Operating Display Entry Displayed value or function, required input [PV] Display of actual process value, entry (= physical unit) depending on process value SETP [PV] input of setpoint, entry (= physical unit) depending on process value MODE input of controller mode −...
Page 37: Controller Operation In General
Operators Handbook DCU3 – System 6., Main function „Control Loops“ Controller Operation in General In general the operation of the DDC-controller is almost the same. Operation includes the necessary changes of the setpoints, of the controller modes and of the controller outputs. Additional controller settings not required for routine operation, will be done via the parametrization functions.
Page 38: Parametrization Of Controllers, In General
Operators Handbook DCU3 – System 6., Main function „Control Loops“ Parametrization of Controllers, in General For optimum adaptation of the DDC controllers to the control loops of the fermentor, the operator can change important control parameters of individual controllers via the parametrization displays: MIN, MAX Minimum and maximum limits for the controller output DEADB...
Page 39 Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.4.3 Operating Display Entry Displayed value or function, required input Input of minimum output limit, representing the setpoint minimum for the servo controller (0 ... 100 % = measuring range of process value) Input of minimum output limit, representing the setpoint minimum for the servo controller (0 ...
Page 40 Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.4.4 PID-Parameter The PID - controllers can be optimized via the PID - parameters Xp, TI and TD in the corresponding entries of the menu. The implemented digital controllers allow changes of the control behavior (P, PI, PD, PID) and of the parameters during operation, which simplifies the optimization of the controllers.
Page 41: Temperature Controller
Operators Handbook DCU3 – System 6., Main function „Control Loops“ Temperature Controller The temperature is controlled via a cascade control with a master controller for the vessel temperature and a servo controller for the jacket temperature. The output of the servo controller controls the steam valve (or an electric heater) and the cooling valve in split-range operation via pulsewidth-modulated or continuous outputs.
Page 42 Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.5.2 Operating Display for Servo Controller (Jacket Temperature) For a description of the tags, the physical units or entries, the displayed value or function and of the required inputs see the table in section 6.3, Controller Operation in General. 6.5.3 Operation For routine adjustment of setpoint and operating mode only the master controller [TEMP]...
Page 43: Stirrer Speed Controller
Operators Handbook DCU3 – System 6., Main function „Control Loops“ Stirrer Speed Controller The speed of the stirrer motor is controlled via an external, extra motor controller. You will adjust all stirrer speed parameters at the DCU3 system. The control function of the DCU3 system works as a setpoint controller and supplies the analog setpoint signal to the motor controller.
Page 44: Airflow Controller
Operators Handbook DCU3 – System 6., Main function „Control Loops“ Airflow Controller The airflow is controlled via an external massflow controller. The airflow control function of the DCU3 - system works as a setpoint controller. It supplies the analog setpoint signals to the external massflow controller .
Page 45: Ph - Control Function Operating As Pid - Controller
Operators Handbook DCU3 – System 6., Main function „Control Loops“ pH - Control Function Operating as PID - Controller The pH - control function of the DCU system usually works in PID - behavior. The pH - control function triggers the corrective agent pumps (or dosing valves) in split-range mode via two pulsewidth- modulated outputs.
Page 46: Po 2 -Control Methods
Operators Handbook DCU3 – System 6., Main function „Control Loops“ -Control Methods Contrary to the other controls of fermentor systems (temperature, pH etc.) the pO - control is adapted to the specific process requirements. For this the DCU3 - system comprises different pO - controllers that can be implemented according to the selected process.
Page 47 Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.10.1 Operating Display pO - Cascade Controller For a description of the tags, the physical units or entries, the displayed value or function and of the required inputs see the table in section 6.3, Controller Operation in General. Additional functions of this Operating Display are the following: Entry Displayed value or function, required input...
Page 48 Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.10.1.1 Parametrization Display pO - Cascade Controller with 3 Servo Controllers Entry Displayed value or function, required input DEADB Input of dead band in relation to measuring range (0 - 100 % sat) Hyst.
Page 49 Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.10.1.3 Special Notes When the pO controller is in „auto“ or „profile“ mode, the selected servo controllers are automatically switched to „cascade“ mode. When the pO controller is in „off“ mode, the selected servo controllers are switched auto- matically to „off“.
Page 50: Po 2 - Cascade Controller With 4 Servo Controllers
Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.11 - Cascade Controller with 4 Servo Controllers This cascade controller operates in the same manner as the pO2 cascade controller with 3 servo con- trollers. The only difference is the fact, that 4 of the possible 4 servo controllers can be controlled. 6.11.1 Operating Display pO - Cascade Controller with 4 Servo Controllers...
Page 51 Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.11.2 Parametrization Display pO - Cascade Controller with 4 Servo Controllers Entry Displayed value or function, required input DEADB Input of dead band in relation to measuring range (0 - 100 % sat) Cascade [Controller] Display of the selected servo controller with its parameters Minimum...
Page 52: Enrichment
Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.12 -Gasmix Controller / O – Enrichment The DCU3 - system can control the pO by mixing of two gases, e.g. N and O , via the pO Gasmix controller. This controller directly triggers the valves for N in splitrange mode via pwm outputs.
Page 53: Po 2 - Gasflow Ratio Controller
Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.13 - Gasflow Ratio Controller To improve the control quality, the pO can also be controlled by means of continuously mixing of two gases, e.g. O and air, via an external massflow controller. The DCU3 - system realizes such a control strategy by a cascade control with a pO gasflow controller as the master controller and a gasflow ratio controller as the servo controller.
Page 54 Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.13.2 Operating Display Servo Controller (Gasflow Ratio Controller) For a description of the tags, the physical units or entries, the displayed value or function and of the required inputs see the table in section 6.3, Controller Operation in General. Above this the display has the following entries and functions for these inputs: Entry Displayed value or function, required input...
Page 55 Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.13.3 Parametrization Display Servo Controller (Gasflow ratio controller) Entry Displayed value or function, required input TOTAL MIN Enter minimum output limit for total flow TOTAL MAX Enter maximum output limit for total flow RATIO MIN Enter minimum output limit for ratio of gas 1 RATIO MAX...
Page 56: Oxygen (O ) - Enrichment Using 2 Massflow Controllers
Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.14 Oxygen (O ) – Enrichment Using 2 Massflow Controllers 6.14.1 Functional Principles The control method „O -Enrichment using 2 massflow controllers“ acts in two phases, „Gasflow Total“ and „Gasflow Ratio“: The pO is controlled by air supply until a user definable maximum flowrate is achieved.
Page 57 Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.14.3 Operating Display O -Enrichment Controller For a description of the tags, the physical units or entries, the displayed value or function and of the required inputs see the table in section 6.3, Controller Operation in General. Additional functions of this Operating Display are the following: Entry Displayed value or function, required input...
Page 58: Foam Controller
Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.15 Foam Controller When foam comes into contact with the antifoam sensor, the foam measurement amplifier generates a limit value signal for the antifoam controller. This signal is active as long as foam has contact with the probe.
Page 59 Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.15.2 Operation Leakage currencies or deposits on the sensor can cause erroneous activation of the foam control, resulting in an excess dosage of antifoam agent. In order to avoid such an errone- ous activation the sensitivity of the foam sensor should be set as low as possible.
Page 60: Dosing Pump Controller
Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.16 Dosing Pump Controller The implemented dosing pump controller can control an external, continuous pump for the addition of nutrient solution. The dosing pump control function provides a setpoint control of the external pump (remote control) and transmits the analog setpoint signals to the pump.
Page 61: Level Controller
Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.17 Level Controller 6.17.1 Control Principles The level control function of the DCU3 - system allows for a simple level control by means of height- adjustable conductive level probes. The probe will be connected to the „Level“ measurement amplifier of the DCU3 system whose the limit output signal acts as input on the level controller.
Page 62 Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.17.2 Operating Display Entry Displayed value or function, required input LEVHI on / off Signal of level sensor (on = level exceeds the limit) MODE Input of controller mode − controller off, harvest and feed pump off −...
Page 63: Weight Controller
Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.18 Weight Controller Fermentation processes often require to keep the culture volume precisely constant, i.e. during con- tinuous or „repeated fed batch“ operation. Compared to level control the weight control is another suit- able, more precise method to control the vessel contents.
Page 64: Pressure Controller
Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.19 Pressure Controller For control of the pressure inside a culture vessel the DCU system comprises a PID controller with continuous output. The corresponding analogue output signal 0...20 mA of the DCU3 - system controls a continuous control valve in the exhaust line via an I/P converter.
Page 65: Gravimetric Dosing Controller
Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.20 Gravimetric Dosing Controller The „Flow controller“ is a precise gravimetric dosing controller. It will be used together with a balance system. Balance systems suited and tested for the DCU - system are the MC1-type balance by Sarto- rius, Fed.
Page 66 The accuracy given below for the FLOW-controller has been evaluated using a balance system type MC1 - LC 6200, by Sartorius, Fed. Rep. of Germany and a dosing pump FE 211 by Sartorius BBI Sys- tems GmbH. The working range of the balance system was 0 ... 6,200 g at a resolution of 0.1 g. The pump was equipped with pump head type „F: 0.1“...
Page 67: Setpoint Profiles
Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.21 Setpoint Profiles Most of the configured control loops can be operated with time-based setpoint profiles („control loop profiles“). A profile will be entered into a table via the operator terminal. A profile can include step changes and ramp changes with a maximum of 16 segments.
Page 68 Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.21.2 Operation We recommend to prepare a scheme of the intended profile with all break points and the corresponding setpoints (see example below). The breakpoints of the scheme will give you the time settings and setpoints, which must be programmed.
Page 69: Timers
Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.22 Timers The timers implemented in the DCU3 - system can switch off and on discontinuous actuators and pumps, for instance, via digital outputs. For this the timers can be operated in these operating modes: In cycle mode the output is switched on and off periodically.
Page 70 Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.22.2 Operation The timers can run in profile mode or in cyclical mode. See below some examples for such modes. Fig. 7-2 Example for timer operation in cyclical mode Fig. 7-3 Example for timer operation in profile mode 6.22.3 Special Notes...
Page 71: Alarm Limits Of Process Values
Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.23 Alarm Limits of Process Values The DCU3 - system includes alarm handling routines which monitor all process values (measured val- ues and derived process values), whether they are within their alarm limits. For the monitored process values the high/low alarm limits are entered via the operator terminal at first.
Page 72 Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.23.2 Special Notes Alarms will be displayed and can be answered as follows : When an alarm occurs for the first time, an alarm message is generated and displayed. Press the „ACK"nowledge key to confirm. This also deletes this alarm message. The display of the process value changes its colour to red.
Page 73: Alarms Of Digital Inputs
Operators Handbook DCU3 – System 6., Main function „Control Loops“ 6.24 Alarms of Digital Inputs The DCU3 - system can also monitor the status of digital inputs for alarm conditions. This includes monitoring of limiters, motor protectors and circuit breakers. The digital alarms must be enabled via the operator terminal.
Page 74: Baedcu3 - Rev. 4
Operators Handbook DCU3 – System 6., Main function „Control Loops“ BAEDCU3 - Rev. 4.6 - 0504 6 - 40...
Page 75: Main Function „Batch Control
Operators Handbook DCU3 – System 7., Main function „Batch Control“ MAIN FUNCTION „BATCH CONTROL“ General The main function „Batch control“ is used for supervisory functions for process control and running of automatic processes (such as a „sterilization program“, for instance). You can select the following functions via a corresponding selection menu: Selection Menu „Batch Control“: Sequences...
Page 76 Operators Handbook DCU3 – System 7., Main function „Batch Control“ 7.2.1 Sterilization Programs The sterilization programs in general are phase controls. They have automatic access to digital out- puts for valve control (max. 64 outputs), to controller setpoints and modes and to alarm parameters for limit monitoring.
Page 77 Operators Handbook DCU3 – System 7., Main function „Batch Control“ 7.2.2 Operating Display „Automatic Sequential Control“ ® Note: This example is only valid for BIOSTAT Entry Displayed value or function, required input STATE Enter the sterilization program mode „start“ or „stop“ −...
Page 78 Operators Handbook DCU3 – System 7., Main function „Batch Control“ 7.2.3 Operation Automatic Sterilization Control Carry out the operations at the fermentor required for preparing the sterilization sequence, see the Operating Manual of the fermentor for details. If necessary, adjust the sterilization parameters (sterilization temperature, time etc.) Start the sterilization program with [STATE: start].
Page 79: Process Time
Operators Handbook DCU3 – System 7., Main function „Batch Control“ Process Time A „process time“ can be displayed in the headline of the operating display in addition to the continuous display of the actual date and time. For this the DCU3 - system includes an extra process time clock. It is possible to start the process time clock at zero or at a predefined time.
Page 80 Operators Handbook DCU3 – System 7., Main function „Batch Control“ BAEDCU3 - Rev. 4.6 - 0504 7 - 6...
Page 81: Main Function „Recipes
Operators Handbook DCU3 – System 8., Main Function „Recipes“ MAIN FUNCTION „RECIPES“ Overview All process parameters that you usually enter or alter manually during the fermentation process, can be predefined and stored in recipes. Hence they can be activated as complete parameter sets during the running process.
Page 82 Operators Handbook DCU3 – System 8., Main Function „Recipes“ After selecting a recipe you can select the recipe parameter sets via the following menu: BAEDCU3 - Rev. 4.6 - 0504 8 - 2...
Page 83: Controller Parameters In Recipes
Operators Handbook DCU3 – System 8., Main Function „Recipes“ Controller Parameters in Recipes For all configured controllers you can specify and store the controller parameters „setpoints“, „control- ler modes“ or „controller outputs“ in recipes. Inputs will be made similar to those in the main function „Control Loops“.
Page 84: Setpoint Profiles
Operators Handbook DCU3 – System 8., Main Function „Recipes“ Setpoint Profiles In recipes you can specify setpoint profiles for all configured controllers. Inputs will be made similar to those within the main function „Parameters“. When a recipe is loaded all profiles can be started simul- taneously, if they all are set to „start“...
Page 85: Timers In Recipes
Operators Handbook DCU3 – System 8., Main Function „Recipes“ Timers in Recipes You can also activate all configured timers via the recipe. All timers can be started simultaneously while a recipe is loaded. For this the timers must be set to „start“ in the recipe. If a timer should not be started when the recipe is loaded, they must be set to „no change“...
Page 86: Process Value Alarms In Recipes
Operators Handbook DCU3 – System 8., Main Function „Recipes“ Process Value Alarms in Recipes You can specify the upper and lower alarm limits and the alarm status for each process variable in a recipe. All inputs must be made as described in chapter 6.23, Alarm Limits of Process Values. If the recipes should not influence the alarm monitoring for certain process variables, the alarm state must be set to „no change“...
Page 87: Digital Input Alarms
Operators Handbook DCU3 – System 8., Main Function „Recipes“ Digital Input Alarms An alarm monitoring for digital inputs („Digital Input Alarms“) can also be specified in a recipe. For this all inputs must be made as described in chapter 6.24. If the alarm monitoring of a digital input should not be influenced by a recipe, the alarm state of this digital input must be set to „no change“...
Page 88 Operators Handbook DCU3 – System 8., Main Function „Recipes“ BAEDCU3 - Rev. 4.6 - 0504 8 - 8...
Page 89: Main Function „Maintenance
Operators Handbook DCU3 – System 9., Main function „Maintenance“ MAIN FUNCTION „MAINTENANCE“ Overview The DCU3 - system offers several functions for system maintenance and trouble shooting in the main function „Maintenance“. The operator can select the functions listed below via a selection menu: 9.1.1 Selection Menu „Maintenance“...
Page 90: Manual Operation In General
Operators Handbook DCU3 – System 9., Main function „Maintenance“ Manual Operation in General During start-up of the DCU3 - system together with the fermentor and for trouble shooting all analog and digital process inputs and outputs and the DCU - internal in- and outputs can be switched over to manual operation.
Page 91 Operators Handbook DCU3 – System 9., Main function „Maintenance“ 9.3.2 Abbreviations (TAGs) for Digital Process Inputs For a complete listing of the tags for digital inputs please refer to the supplement. Reserve inputs are defined by their physical channel assignment: –...
Page 92: Manual Operation For Digital Outputs
Operators Handbook DCU3 – System 9., Main function „Maintenance“ Manual Operation for Digital Outputs For manual operation you can disconnect a digital output from its internal DCU - function and adjust manually. You can switch static outputs, such as valve controllers, „on“ and „off“. For pulse-width modulated outputs you can enter the pulse control factor in terms of [%].
Page 93 Operators Handbook DCU3 – System 9., Main function „Maintenance“ Column Entry Meaning I/O Addr., Tag Name DOP01 HEAT, Tag of digital output; setting of operating DOP02 FEEDP, etc. “MODE” and status of “value” entry Mode auto normal operation, DCU triggers the output lock (display only) output is switched via locking function, such as alarm locking...
Page 94: Manual Operation Of Analog Inputs
Operators Handbook DCU3 – System 9., Main function „Maintenance“ Manual Operation of Analog Inputs In the manual mode you can disconnect an analog input, e.g. a measurement amplifier signal, from the external equipment and simulate the input by entering a relative signal level (0 ... 100%). 9.5.1 Operating Display Column...
Page 95 Operators Handbook DCU3 – System 9., Main function „Maintenance“ 9.5.3 Special Notes The physical signal level for internal analog inputs (AIM) is always 0 ... 10 V (= 0 ... 100%). For external analog inputs (AIP) the physical signal level can configured within : –...
Page 96: Manual Operation For Analog Outputs
Operators Handbook DCU3 – System 9., Main function „Maintenance“ Manual Operation for Analog Outputs You can disconnect all analog outputs from the internal DCU functions and adjust the output signal manually within a relative signal level of 0 ... 100 %. Output signals have the following order of priority: Highest priority - shut down - manual operation...
Page 97 Operators Handbook DCU3 – System 9., Main function „Maintenance“ 9.6.2 Abbreviations (TAGs) of Analog Outputs For a complete list of abbreviations (TAGs) of analog outputs refer to the supplement. Unassigned spare outputs have their physical channel assignment as TAG. Example: –...
Page 98: Settings Of Measurement Ranges
Operators Handbook DCU3 – System 9., Main function „Maintenance“ Settings of Measurement Ranges The main function „Maintenance“ allows for changing the thresholds (lower and upper limits) of the measuring ranges for all process values. The settings preconfigured on delivery correspond with the fermentor system to which the DCU3 - system is assigned to.
Page 99: Connection Of External Devices
Operators Handbook DCU3 – System 9., Main function „Maintenance“ Connection of External Devices The DCU3 - system has, by default, 2 serial interfaces for the connection of external devices, such as printers, recorders, host computer, etc. The adjustments required for communication will be done in the function „External Systems“...
Page 100: Host Interface
Operators Handbook DCU3 – System 9., Main function „Maintenance“ Host Interface For communication with a host computer via the serial interface RS 422/485 or the Ethernet interface (HOST) the DCU system offers a flexible communication protocol. By means of the RS422 /485 or the Ethernet interface you can establish a bus system for communication with several DCU systems.
Page 101 Operators Handbook DCU3 – System 9., Main function „Maintenance“ 9.9.2 Default Settings for Micro-MFCS Host Computer ADDRESS 1 ... 8 PORT RS 422 BAUDRATE 9600 Baud DATABIT 7 bit STOPBIT 1 bit PARITY even 9.9.3 Special Notes „DCU-address“ must be the same address, which had been assigned during installation of the host computer.
Page 102: Peripheral Interface
The interface parameters shown above are only valid for a protocol printer. If a balance sys- tem (a Sartorius type balance, for instance) or host computer is connected (via RS232, for instance) these parameters do not have any effect and cannot be changed.
Page 103: Balance Interface
Operating Display Entry Displayed value or function, required input PROTOCOL Selection of balance protocol Sartorius Protocol SARTORIUS (all actual / new balance systems) Mettler Protocol METTLER (MT-SICS-LEVEL 0 and previously supplied balance systems PM/SM/AM) ALARM Display of alarms which occur on the serial interface during data...
Page 104: System Settings
Operators Handbook DCU3 – System 9., Main function „Maintenance“ 9.12 System Settings The maintenance function „System Parameter“ can be used for general settings of the DCU - system, such as setting the internal clock. 9.12.1 Operating Display Entry Displayed value or function, required input BEEPER Switching the beeper „on“...
Page 105: Service / Diagnostics
– controller parameters – measuring ranges – communication parameters 9.13 Service / Diagnostics This submenu (level of operation) is only accessible for authorized service personnel and staff of the Sartorius BBI Systems GmbH. BAEDCU3 - Rev. 4.6 - 0504 9 - 17...
Page 106 Operators Handbook DCU3 – System 9., Main function „Maintenance“ BAEDCU3 - Rev. 4.6 - 0504 9 - 18...
Page 107: Main Function „Documentation
Operators Handbook DCU3 – System 10., Main Function „Documentation“ MAIN FUNCTION „DOCUMENTATION“ The main function „Documentation“ is used to enable several functions for process documentation: Protocol printer Recorder configuration 10.1 Selection Menu 10.2 Report Printer The DCU3 - system has an integrated interface for connection of a report printer. If the interface is not used for a serial balance system, it is possible to print process reports via this interface.
Page 108 Operators Handbook DCU3 – System 10., Main Function „Documentation“ 10.2.1 Operating Display Entry Displayed value or function, required input NAME 1 ... 6 input of the name of the record: 12 selectable characters ALARM selection of the printing state of the alarm record −...
Page 109: Recorder Configuration
Operators Handbook DCU3 – System 10., Main Function „Documentation“ 10.3 Recorder Configuration Optionally the DCU system can have a recorder output board. This board offers 6 analog outputs 0 ... 10 V for the connection of a 6-channel dot printer. The 6 recorder outputs must be assigned to the process values in the DCU - system via the main func- tion „Documentation“.
Page 110 Operators Handbook DCU3 – System 10., Main Function „Documentation“ BAEDCU3 - Rev. 4.6 - 0504 10 - 4...
Page 111: Main Function „Password
Operators Handbook DCU3 – System 11., Main Function „Password“ MAIN FUNCTION „PASSWORD“ Several system functions and settings which should only be accessible for authorized personal, are protected by the standard password system. This is especially true for the setting of controller parame- ters (PID, etc.), the setting of interface parameters and the manual operation.
Page 112 Operators Handbook DCU3 – System 11., Main Function „Password“ Changing the standard password Field Entry Function, required input PASSWORD 0 .. 9 Enter the standard password Special Notes After a software reset the default setting for the standard password („9“) is available again The multi level passwort system is described in details in the separate manual „Multi Level Passwort System for DCU3 - System“.
Page 113: Main Function „Info
Operators Handbook DCU3 – System 12., Main Function „INFO“ MAIN FUNCTION „INFO“ The operator can call for several information via the main function „Info“, i.e. such as: System parameters Hotline Display „Info“ Field Entry Function, required input Software Vers. Display of actual version of the implemented software Configuration Display of the installed functional configuration Internet...
Page 115: Alarms
Operators Handbook DCU3 – System 13., Alarms ALARMS 13.1 Alarm Messages Alarm Messages will be displayed in the second line of the touch - display (and, if connected, on a re- mote terminal). The messages include a short reference for the kind of alarm and, in the right part of the display, date and time when the alarm occurred.
Page 116: Alarm Menu
Operators Handbook DCU3 – System 13., Alarms 13.2 Alarm Menu 13.2.1 Selection of Menu The alarm menu can be selected as follows: Pressing the direct function key „ALARMS“ Pressing the alarm line of the touch display 13.2.2 Operating Display Entry Displayed value or function, required input Confirmation of single alarms ACK ALL MESSAGES...
Page 117: Supplement
Operators Handbook DCU3 – System 14., Supplement SUPPLEMENT 14.1 Alarms, Meanings and Remedial Measures (Troubleshooting) 14.1.1 Process Alarms The operator can individually switch-on and off the alarms referred to in the table below : Text of alarm line Meaning Remedial measures „Name State alarm ...“...
Page 118 Operators Handbook DCU3 – System 14., Supplement 14.1.3 System Alarms The alarms included in the table below are set from the system and cannot be switched-off: Text of alarm line Meaning Remedial measures „DCU Reset HH:MM ...“ System confirms enabling of a system Confirm alarm with 'ACK'nowl- reset via the maintenance menu, with edge...
Page 119 Operators Handbook DCU3 – System 14., Supplement 14.1.4 Service and Installation Messages Text of alarm line Meaning Remedial measures „1.FIB/not inst./102“ FIB missing or installed incorrectly Check board address; reset to delivery state; send a claim note for the FIB „1.FIB/AI01-16 /175“...
Page 120 Operators Handbook DCU3 – System 14., Supplement Text of alarm line Meaning Remedial measures „3.FIB/AI01-16 /175“ The analog inputs AIP01...AIP17 of the Send a claim note for FIB 3rd FIB are malfunctioning „3.FIB/AI17-32 /175“ The analog inputs AIP17..AIP32 of the Send a claim note for FIB 3rd FIB of the analog input extension are are malfunctioning...
Page 121: Trouble Shooting For The Dcu-System
The operator or the customers´ service can use the form „Function bug handling“ which is available on request, to describe the problem. If all aspects are considered this will enable the Sartorius BBI Sys- tems GmbH to answer within the shortest possible time offering a solution for the problem.
Page 122: Abbreviations
Operators Handbook DCU3 – System 14., Supplement 14.4 Abbreviations All entries in the operation display depend on the individual configuration of the DCU- system. The standard configurations use the following terms : 14.4.1 Process Values Abbreviation Meaning TEMP Temperature culture vessel JTEMP Temperature double wall STIRR...
Page 123 Operators Handbook DCU3 – System 14., Supplement 14.4.2 Digital - Inputs Displayed value or function, required input FOAM status signal from foam sensor LEVEL status signal from level sensor for level measurement (medium has contact with the sensor) TEMPC alarm message; requires check of Pt100 in culture vessel JTMPC alarm message;...
Page 124: Fermentor - Specific Adjustments Of Balance Systems
If you miss specific information concerning your special equipment, please contact your lo- cal representative of Sartorius BBI Systems GmbH for further support or write directly Dept. Automation of Sartorius BBI Systems GmbH, see address given in the next section.
Page 125: Arrangement And Assignment Plans
By the „Declaration of Conformity“, which may be enclosed in this document or can be de- livered extra, the Sartorius BBI Systems GmbH confirms, that the DCU - system fulfills the requirements of all mentioned EC-directives, harmonized and national standards and tech- nical specifications.
Page 138 Operators Handbook DCU3 – System 14., Supplement BAEDCU3 - Rev. 4.6 - 0504...
Page 150 Operators Handbook DCU3 – System 14., Supplement BAEDCU3 - Rev. 4.6 - 0504...

Sartorius DCU 3 Operator's Handbook Manual

1 Design and Function

2 Operating Behaviour

3 Function Selection and Inputs

4 Start-Menü „Main

5 Main Function „Calibration

6 Main Function „Control Loops

7 Main Function „Batch Control

8 Main Function „Recipes

9 Main Function „Maintenance

10 Main Function „Documentation

11 Main Function „Password

12 Main Function „INFO

Alarms

Supplement

Quick Links

Troubleshooting

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Summary of Contents for Sartorius DCU 3

Table of Contents