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Summary of Contents for Applikon ez-Control
- Page 1 In Situ sterilizable Bioreactors HARDWARE MANUAL Project 310420; PS 70L, IST (AU)
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Page 2: Table Of Contents
HARDWARE MANUAL CONTENTS ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) TABLE OF CONTENTS SAFETY ..............................4 Safety Symbols ..........................4 Safety Warnings ..........................5 EU Declaration of Conformity ......................7 GENERAL ..............................8 Introduction ............................8 System View ............................8 Emergency Stop Button ........................9 Right-Side View ..........................9... - Page 3 All rights reserved. This set of documents is protected by copyright law. It may not be reproduced, stored or made public in any form by any means without the prior written approval of Applikon Biotechnology B.V. Applikon Biotechnology B.V. Heertjeslaan 2...
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Page 4: Safety
HARDWARE MANUAL SAFETY ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) 1 SAFETY SAFETY SYMBOLS The following symbols are used on the equipment and in this manual. WARNING Risk of personal injury or danger to life. WARNING Risk of electrical shock hazard. -
Page 5: Safety Warnings
WARNING Risk of physical hand injury caused by pumps. • In most cases, one or more pumps are installed in the ez-Control. • According to the European Community legislation on machinery, a pump drive is a machine with potential hazard. Only apply these drives with the pump heads and tubing that are described in this manual (chapter: pumps)! •... - Page 6 Verify the tube quality inside the pump head before every fermentation run. Additional information • Do not apply an Earth Leakage Circuit Breaker in the power supply of the Applikon control equipment (in an industrial environment or laboratory, an earth leakage circuit breaker is not mandatory). •...
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Page 7: Eu Declaration Of Conformity
SAFETY ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) EU DECLARATION OF CONFORMITY The company Applikon Biotechnology B.V., residing in Delft, The Netherlands, hereby certifies that the instrument: ez-Control In Situ sterilizable Bio Reactor Systems meets the requirements of the following Directive of the European Union:... -
Page 8: General
• A wet part for temperature control and steam sterilization. • An ez-Control for measurement and control of process variables (pH, temperature, DO, level, pressure, and stirrer speed) with corresponding controller outputs in order to keep process conditions on set-point. -
Page 9: Emergency Stop Button
HARDWARE MANUAL GENERAL ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) EMERGENCY STOP BUTTON The Emergency Stop button is located at the left upper corner of the cabinet. If the Emergency Stop button is pressed, all actuators are switched off (to default position). -
Page 10: Rear View
2 A. In case additional I/O (inputs and/or outputs) are required, the Extended I/O Module will be mounted at the rear of the ez-Control. For more information, refer to the Extended I/O Manual. The SIP Control Connections are connected to the SIP Actuator Module that is located... - Page 11 The air in- and outlets are Quick Connectors for tubing OD = 10 mm. Required inlet pressure for the gasses: 2 barg. Bottle rack The ez-Control Bottle Rack for Reagent Bottles is optional. It is available in two versions: Z310113010 Bottle Rack 3 x 0.5 liter bottles...
- Page 12 HARDWARE MANUAL GENERAL ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) The table below lists the actuator connectors and their functions. The valve notation like V(Y)-2.04 means that it may represent a valve that is pneumatically (V-2.04) or electrically (VY-2.04) driven.
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Page 13: Sensor Input Specifications
• Pollution: Pollution degree 2 in accordance with IEC 664 • Power consumption: P-max = 1300 VA CLEANING INSTRUCTIONS The ez-Control for In Situ sterilizable Bioreactor Systems may be cleaned with a moist tissue in combination with a non-abrasive cleaner. -
Page 14: Actuators
HARDWARE MANUAL ACTUATORS ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) 3 ACTUATORS The Actuator control part of the ez-Control supports the following actuators: • pH control: acid / base addition or aeration with carbon dioxide •... -
Page 15: Valves In Gas Supply Lines
HARDWARE MANUAL ACTUATORS ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) 3.1.2 VALVES IN GAS SUPPLY LINES At the inner rear side of the gas supply drawer, per gas a solenoid valve is mounted before the mass flow controller. -
Page 16: Actuators For Temperature Control
HARDWARE MANUAL ACTUATORS ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) ACTUATORS FOR TEMPERATURE CONTROL The wet part of the system contains actuators for temperature control during cultivation and sterilization. During cultivation, water is circulated through the jacket of the reactor. The temperature in the reactor is controlled by either electrical heating or introducing cold water into the jacket of the reactor. -
Page 17: Pumps And Tubing
HARDWARE MANUAL ACTUATORS ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) PUMPS AND TUBING At the Pump Section up to three tubing pump drives with pump heads may be installed. The figure shows the default pump configuration. -
Page 18: How To Load The Tubing
Open the cover Place the tube in lower clip The pump with 102R head must be started manually from ez-Control. The Prime function can be used (Menu->Tubing pump control->Prime) Carefully load the tubing in the pump head: watch your fingers! -
Page 19: Actuator Control
HARDWARE MANUAL ACTUATORS ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) ACTUATOR CONTROL 3.5.1 DISCRETE ACTUATORS VERSUS CONTINUOUS ACTUATORS Discrete (digital) actuators like valves and pumps are controlled in a “Pulse-Width Modulated” manner (PWM): • within a predefined “cycle time”, the output (Actuator) is switched on during the “On-time”... -
Page 20: Agitation
4 AGITATION INTERNAL STIRRER SPEED CONTROLLER The internal stirrer speed controller of the ez-Control is used to drive the stirrer motor on top of the bioreactor. Depending on the reactor size and required stirring power, different stirrer motors can be used. -
Page 21: Stirrer Motor Specifications
HARDWARE MANUAL AGITATION ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) STIRRER MOTOR SPECIFICATIONS 4.3.1 MOTOR P100, I=6 Standard Top Stirrer motor for cell culture bioreactors with a standard stirrer speed range of 0 to 200 rpm. -
Page 22: Power Supplies For Stirrer Motor Assemblies
HARDWARE MANUAL AGITATION ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) POWER SUPPLIES FOR STIRRER MOTOR ASSEMBLIES Z310110130 Power Module SIP Standard for P100 Z310110140 Extended Power Module SIP Extended 230 VAC for P1000 Z310110150 Extended Power Module SIP Extended 115 VAC for P1000... -
Page 23: Reactor
HARDWARE MANUAL REACTOR ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) 5 REACTOR GENERAL REACTOR CONSTRUCTION The main components (vessel, jacket, tubing, frame) of the reactor are made of SS 316L (1.4404) stainless steel. The sight glass is made of borosilicate, and the gaskets and O-rings are made of silicone, EPDM or PTFE. -
Page 24: Reactor
HARDWARE MANUAL REACTORS ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) 70L REACTOR The insulated Bioreactor 70L is designed and built according to the following specifications: Part Number V6L1130711 Total Volume 73 L Working Volume 50 L Min. -
Page 25: Head Plate Port Specifications
HARDWARE MANUAL REACTOR ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) HEAD PLATE PORT SPECIFICATIONS Port Number Port Size Description 69 mm Blind Plate (spare) 16 mm Level / Foam Sensor 16 mm Blind Stopper (spare) 16 mm... -
Page 26: Utility Connections
HARDWARE MANUAL REACTORS ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) UTILITY CONNECTIONS The Wet Part of the Bioreactor System has utility connections for water, steam, biowaste and drain. In the image and table below, the different connections are described (rear view of wet part). -
Page 27: Auxiliaries
HARDWARE MANUAL AUXILIARIES ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) 6 AUXILIARIES This chapter describes the reactor auxiliaries, i.e. devices that can be mounted in the head plate, sidewall or bottom. STIRRER ASSEMBLY The bioreactor is equipped with: •... -
Page 28: Optimum Impeller Configuration
HARDWARE MANUAL AUXILIARIES ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) OPTIMUM IMPELLER CONFIGURATION The following images show the advised impeller configuration (position and diameter) for stirred tank bioreactors (microbial and cell culture): Microbial Culture H/D ~ 1.5 …. 2.5... -
Page 29: Power Required For Stirring
HARDWARE MANUAL AUXILIARIES ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) 6.2.1 POWER REQUIRED FOR STIRRING The power (Watt) of the stirrer motor that is required depends on the number, type and diameter of the impellers, density of the medium and the stirrer speed. The required power per impeller of a stirrer motor in non-aerated media is given by the equation: P = ρ... -
Page 30: Aeration
HARDWARE MANUAL AUXILIARIES ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) AERATION This section describes the reactor auxiliaries for gas supply (inlet and outlet). For information concerning rotameters, mass flow controllers, valves, etc., refer to Section 3.1. -
Page 31: Auxiliaries For Aeration
HARDWARE MANUAL AUXILIARIES ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) 6.3.1 AUXILIARIES FOR AERATION The bioreactor is aerated through a sparger- and overlay inlet (ports in the side wall of the bioreactor). See schematic presentation below:... -
Page 32: Off-Gas Line
HARDWARE MANUAL AUXILIARIES ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) 6.3.2 OFF-GAS LINE The off-gas leaves the reactor through the condenser, the off-gas filter and the exhaust valve. See schematic image below: Due to the Electric Heater between the Condenser and the Off-gas Filter, condensate formation on the filter surface is prevented. -
Page 33: Auxiliaries For Addition
HARDWARE MANUAL AUXILIARIES ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) AUXILIARIES FOR ADDITION Additions can be performed through the use of push valves and contained addition assemblies. In this project, only Push Valves are used. 6.4.1 PUSH VALVE ASSEMBLY The push valve assembly is designed for easy, aseptical addition through 16 and 27 mm ports in the head plate or upper sidewall section of the bioreactor. -
Page 34: Auxiliaries For Drain
HARDWARE MANUAL AUXILIARIES ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) AUXILIARIES FOR DRAIN The bottom drain is used for taking relatively large samples from the culture and for harvesting / draining the system after finishing the process. -
Page 35: Safety Devices
HARDWARE MANUAL AUXILIARIES ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) SAFETY DEVICES 6.6.1 PRESSURE GAUGE A pressure gauge is required in a bioreactor and in the jacket in order to monitor the pressure in the system. -
Page 36: Blind Stoppers
The contents can be viewed through the sight glass at the front side of the bioreactor. The illumination assembly contains a 12 V / 10 Watt halogen bulb and an illumination holder, which is mounted at the head plate. For information on usage of this illumination assembly, refer to the ez-Control Software Reference manual. Z821320090... -
Page 37: Sensors
HARDWARE MANUAL SENSORS ez-Control for In Situ sterilizable Bioreactors Project 310420; PS70 IST (AU) 7 SENSORS Several sensors can be used to measure process parameters in the bioreactor. Dependent on the sensor, it can be mounted in a head plate port or in a lower sidewall port.
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