Sartorius Stedim Biotech BIOSTAT B-DCU Operating Instructions Manual
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Sartorius Stedim Biotech BIOSTAT B-DCU Operating Instructions Manual

Bioreactor/fermenter
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Operating Instructions
(Translation of the Original Operating Instructions)
BIOSTAT
B-DCU
®
Bioreactor | Fermenter
85037-549-98

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Summary of Contents for Sartorius Stedim Biotech BIOSTAT B-DCU

  • Page 1 Operating Instructions (Translation of the Original Operating Instructions) BIOSTAT B-DCU ® Bioreactor | Fermenter 85037-549-98...

  • Page 3: Table Of Contents

    Contents Contents 1 About These Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1 .1 Validity .
  • Page 4 Contents 4 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 4 .1 User Information .
  • Page 5 Contents 8 Preparing and Running the Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 8 .1 Overview .
  • Page 6 Contents 8 .8 .8 .3 Performing Recalibration . . . . . . . . . . . . . . . . . . . . . . . . . .104 8 .8 .8 .4 Configuring the Measurement Cycle for pH Measurement .
  • Page 7 Contents 9 .2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158 9 .2 .1 Maintenance Info .

  • Page 8: About These Instructions

    About These Instructions About These Instructions Validity These instructions provide all the information needed to operate the BIOSTAT B-DCU (referred to as the “device” in the following) . These instructions ® apply to the following versions of the device: BIOSTAT ®...

  • Page 9: Target Groups

    About These Instructions Target Groups These instructions are designed for the following target groups . The target groups must possess the knowledge listed . Target group Knowledge | responsibilities User The user is familiar with the operation of the device and the associated work processes .

  • Page 10: Symbols Used

    About These Instructions Symbols Used 1.4.1 Warnings WARNING Denotes a hazard that may result in death or (severe) injury if it is not avoided . CAUTION Denotes a hazard that may result in moderate or minor injury if it is not avoided . ATTENTION Denotes a hazard that may result in material damage if it is not avoided .

  • Page 11: Safety Information

    Safety Information Safety Information Intended Use The device is used as the control unit for various bioreactor systems in combination with the UniVessel Glass or UniVessel SU . This control unit is used to cultivate ® ® biological cultures in liquids or aqueous nutrient solutions under controlled and reproducible conditions .

  • Page 12: Safety Devices

    Safety Information Safety Devices The safety devices of the device protect personnel working with the device from hazards caused by the device, e .g ., electrical current . Do not remove or modify the safety devices (for safety devices, see Chapter 3 .2, page 32) .

  • Page 13: Accessories, Consumables, And Spare Parts

    Safety Information The oxygen line from the gas source to the consumption point must be free from grease and oil . The oxygen line comprises all areas where pure oxygen is routed or that are saturated with pure oxygen . Use only grease and oil-free gases in the cultivation process .

  • Page 14: Personal Protective Equipment

    Safety Information Personal Protective Equipment Personal protective equipment protects against hazards caused by the device or the processed materials . Protective equipment Explanation/examples Protective work Tight-fitting work clothing with low tear resistance, tight clothing sleeves, and without any projecting parts . / Protects users from getting caught by moving parts .

  • Page 15: Escaping Substances

    Safety Information 2.10 Escaping Substances Faulty Components If individual components are damaged, gaseous and liquid substances may escape under high pressure and cause injury to the eyes, for example . Do not start the device without overpressure valves and pressure reducer or comparable overpressure safety devices (such as a burst disk) .

  • Page 16: Danger Of Tripping Or Slipping

    Safety Information 2.14 Danger of Tripping or Slipping Power supply cables that are too long may present a tripping hazard . Hoses that are too long and not secured may present a tripping hazard . Disconnected hoses may cause the floor to become soiled (hose leakages) . This poses a risk of slipping . Therefore: Ensure that power supply cables are properly laid .

  • Page 17: Device Description

    Device Description Device Description Device Overview The device is designed for cultivating microorganisms and cells in discontinuous and continuous processes . It was designed for cultivating microorganisms and cells at various reactor volumes . The device can be used to conduct studies on developing and optimizing fermentation procedures and to perform limited-volume production fermentation processes in a reproducible way .

  • Page 18: Control Unit

    Device Description 3.1.1 Control Unit One to six supply units with different culture vessels can be connected to the control unit . The DCU system of the control unit controls and regulates the connected supply units . The DCU system offers the following functions for each culture vessel connected to a supply unit: −...
  • Page 19 Device Description Description Description Operating display USB port for peripheral devices (with screwable cover) Mains I/O Illuminated push-button − Button: Switches the measurement and control system (DCU system) on − Display: − Light on: Device is switched on − Light off: Device is switched off Potential equalization Mains In Power supply/mains disconnector...

  • Page 20: Supply Unit

    Device Description 3.1.2 Supply Unit The supply unit provides power, gases, and supply media to the connected culture vessel . It forms the interface between the culture vessel and the measurement and control system (DCU system) of the control unit . 3.1.2.1 Front View (with/without Variable Area Flow Meter) Fig .

  • Page 21: Front View Of Connection Panel

    Device Description 3.1.2.2 Front View of Connection Panel Description Description Temp Temperature sensor Pt-100, M12 plug connection pH-A/Redox-A pH sensor A or pH and Redox sensor A, VP8 plug pH-B/Redox-B pH sensor B or pH and Redox sensor B, VP8 plug DO-A DO sensor A, VP8 plug DO-B...

  • Page 22: Rear View Of Connection Panel

    Device Description 3.1.2.3 Rear View of Connection Panel Description Description Ethernet, Connection for control unit, M12 plug connection DCU-Tower Fieldbus Field bus connection, M12 plug connection Serial-A Balance A, serial RS-232/M12 plug connection Serial-B Balance B, serial RS-232/M12 plug connection Balance C, serial RS-232/M12 plug connection Serial-C Balance D, serial RS-232/M12 plug connection...

  • Page 23: Rear View

    Device Description 3.1.2.4 Rear View Fig . 3-4: Rear view of the supply unit Description Potential equalization Manufacturer’s ID label Stirrer connection cable NRTL marking (for 120 V version only) 3.1.3 Aeration The supply units are equipped with the following gas flow controllers: −...

  • Page 24: Variable Area Flow Meter

    Device Description 3.1.3.1 Variable Area Flow Meter Designations on the Variable Area Flow Meter To identify the variable area flow meters, these are labeled with a sticker . The following nomenclature is used: Description Description Air -OV / -SP -OV / -SP Oxygen -OV / -SP Nitrogen...

  • Page 25: Enrichment" And "Gasflow Ratio" Aeration Modules

    Device Description 3.1.3.2 "O Enrichment” and “Gasflow Ratio” Aeration Modules The “O Enrichment” and “Gasflow Ratio” aeration modules supply air and enrich it with oxygen, e .g ., for microbial cultures . Fig . 3-5: "O Enrichment” (one variable area flow meter) and “Gasflow Ratio” (two variable area flow meters) aeration modules with “Sparger”...

  • Page 26: Advanced Additive Flow" Aeration

    Device Description 3.1.3.3 "Advanced Additive Flow” Aeration These aeration modules can supply up to 4 gases and are suitable for cultures with special requirements for the supply of gas (e .g ., CO − for pH regulation, e .g ., in mammalian cell cultures −...

  • Page 27: Peristaltic Pumps

    Device Description "Advanced Additive Flow - 6 out” Aeration Fig . 3-7: "Advanced Additive Flow - 6 out” Aeration In the “Advanced Additive Flow - 6 out” aeration module, aeration takes place with up to 4 gases and up to 6 individual gas outlets . These are by default: −...

  • Page 28: Integrated Peristaltic Pumps

    Device Description 3.1.4.1 Integrated Peristaltic Pumps The peristaltic pumps (2) on the front side of the supply unit pump the correction and nutrient media through hoses into the culture vessel . Up to eight peristaltic pumps can be installed or connected to each supply unit (depending on the configuration) .

  • Page 29: External Pumps

    Device Description 3.1.4.2 External Pumps Four external pumps can be connected to the supply unit (see Chapter 3 .1 .2 .3, page 22) . WM 120 or WM 323 peristaltic pumps are recommended . If other pumps are used, the connector pin assignment must be observed (see Chapter 15 .1, page 182) .

  • Page 30: Temperature Control Modules For Single-Walled

    Device Description Specifications The temperature control module is designed for/fitted with: − 230 VAC, 50 Hz | 120 VAC, 60 Hz electrical connection − Thermostat with 1000 W electric heater 3.1.5.2 Temperature Control Modules for Single-Walled Culture Vessels The temperature control modules contain the power supply for the electrical heating jackets of the single wall culture vessels .

  • Page 31: Stirrer Drive

    Device Description 3.1.6.1 Stirrer Drive Fig . 3-8: Stirrer Drive Description Power supply/connection cable for the supply unit Stirrer drive for culture vessel coupling Motor adapter including motor coupling Stirrers/drives have the following functions: − Top-mounted drive for culture vessels: −...

  • Page 32: Safety Devices And Protective Systems

    Device Description Safety Devices and Protective Systems 3.2.1 Mains Disconnector Control Unit The “Mains In” socket (1) located on the rear side of the control unit is used to connect and disconnect the power supply . Supply Units The “Mains” switch on the front side of the supply unit switches the device off and disconnects the power supply .

  • Page 33: Overheating Protection

    Device Description 3.2.3 Overheating Protection The overheating protection within the device limits the maximum permissible temperature for the temperature control medium . The following temperature control modules can be used: − Water circulation system temperature control − Heating jacket temperature control Symbols on the Device The following symbols are affixed to the device/connected components: Danger of Crushing at the Peristaltic Pump!

  • Page 34: Manufacturer's Id Labels

    Device Description Manufacturer’s ID Labels Control Unit The manufacturer’s ID label is located on the right side panel . Description Description 1000012248 Type Type Device type: 1000012248 No./ 1500100 No . / Year Serial number: 1500100 increasing consecutively Year Mains voltage Current consumption Mains frequency Made in Germany...

  • Page 35: Software

    Software Software User Information These instructions show the standard functions of the DCU software . DCU systems can be customized according to the customer’s specifications . Therefore, this documentation may describe functions that a delivered configuration does not contain or a system may contain functions that are not described here . Information about the actual scope of functionality can be found in the configuration documents .

  • Page 36: Principles Of Operation

    Software For interruptions in operation, the startup behavior of outlets and system functions that have a direct effect on the associated end device (controllers, timers, etc .) depend on the type and duration of the interruption . There are several different types of interruptions: −...

  • Page 37: Header

    Software 4.3.1.1 Header Display of the system status, time, date: − System (type) display − Time in format [hh:mm:ss] − Date in format [yyyy-mm-dd] Alarm display (area marked in red/bell symbol): − Time of the triggered alarm − Type of malfunction −...

  • Page 38: Footer

    Software 4.3.2 Footer Fig . 4-4: Selecting “Main” using the main function key The footer shows the main function keys (see Chapter 4 .3 .4, page 41) for: − Access to the menus for associated main functions: − “Main” − “Calibration” −...
  • Page 39 Software Example “Main” and “1:” − Most important and most frequently used parameters for Unit “1” − Display of all parameters for Unit “1” Display: − Selected main function: light gray key, activated − Function not selected: dark gray keys, deactivated Setting Process Parameters and Monitoring Process Values Depending on the configuration, the BIOSTAT B-DCU can be equipped with up to...

  • Page 40: Display Of Function Elements

    Software 4.3.3 Display of Function Elements The display of the function elements in the work area shows the current status and the intended use . Symbol Display Description [Tag PV] Function element Field for short name (“tag”) for the function element, e .g ., MV [Unit] Key with TEMP, STIRR, pH, DO, ACID, SUBST, VWEIGH, BALANCE...

  • Page 41: Overview Of The Main Function Keys

    Software 4.3.4 Overview of the Main Function Keys Main functions can be selected at any time during a running process . The title of the main function shown in the work area is also displayed in the header . Key, symbol Description “Main”...

  • Page 42: Overview Of Selection Keys

    Software 4.3.5 Overview of Selection Keys Button Description Cancel Changes will not be saved Confirmation of input Further controller parameters Cancel Changes will not be saved Deleting characters Selection of sign when entering a value Selection list of process values 4.3.6 Direct Function Keys for Selection of Submenus The function elements in the work area of the “Main”...
  • Page 43 Software This chapter shows an example of screens and submenus accessible via direct function keys . Example: Input of Temperature Setpoint Fig . 4-5: Setpoint input and selection of the “TEMP” controller mode via the “Main” menu In the work area of the “Main” menu, press the “TEMP” function element or in the work area of the “Controller”...
  • Page 44 Software Fig . 4-6: Setpoint input and selection of the “TEMP” controller mode via the “Controller” menu When the “Controller” menu is accessed, the “Setpoint” key can be used to enter a setpoint (after pressing the key, an on-screen keypad also opens) . The “off” key can be used to select the mode .

  • Page 45: Selection Lists And Tables

    Software 4.3.7 Selection Lists and Tables If submenus contain lists of elements, short names or parameters that cannot be displayed in a window, a scrollbar with a position marker is displayed: Fig . 4-7: Access to values accessible from the submenu after assigning a channel in the trend display To page through lists that contain more entries than can be displayed in the window, the following options are available: Press the “s”...

  • Page 46: User Management

    Software User Management The user management function regulates the access of users to the DCU system . This function makes it possible to grant or restrict access permissions, to prevent incorrect operation of the DCU system, for example . Observe the user management operating instructions for DCU4 systems . Bug Handling and Troubleshooting If the DCU system should encounter technical problems, contact Sartorius Service .

  • Page 47: Transport

    Transport Transport The device will be delivered by Sartorius Stedim Biotech or by a transport company engaged by Sartorius Stedim Biotech . Inspection upon Acceptance by the Recipient 5.1.1 Reporting and Documenting Transport Damage Upon acceptance of the device by the customer: Inspect the device for visible transport damage .
  • Page 48 Transport ATTENTION Danger of damage due to improper transport! Protect the device against: − Impact − Falls − Damage − Humidity Loading/Unloading ATTENTION Danger of damage due to improper loading or unloading! The device must not be unloaded outdoors when it is raining or snowing . The device must also be covered with film, if there is a risk of it getting wet .

  • Page 49: Installation

    Installation Installation The device is set up according to the respective contract conditions by: − Sartorius Service − Sartorius authorized specialist personnel − The customer’s authorized specialist personnel Setting up the device involves the following main steps: − Ensure that the ambient conditions have been fulfilled for the installation location .

  • Page 50: Laboratory Energy Sources

    Installation Laboratory Energy Sources The connections for energy and supply systems must be prepared before installation of the device in the work area . They must be easily accessible, correctly installed, set in accordance with the device’s specifications, and ready to operate . The connections for the supply media are located on the rear panel of the supply units, as well as a voltage connection on the control unit .

  • Page 51: Temperature Control Medium

    − Faults resulting from contaminants or corrosion residues Malfunctions and damages arising from unsuitable water quality are excluded from the warranty granted by Sartorius Stedim Biotech . Green microbes inside the double wall are a sign of algae formation caused by organic contaminants in the water .

  • Page 52: Gas Supply

    − Make sure that the supply gases are dry and free of dirt, oil, and ammonia . − Install suitable filters, if necessary . − Malfunctions and damage arising from contaminated gas media are excluded from the warranty granted by Sartorius Stedim Biotech . BIOSTAT ®...

  • Page 53: Getting Started

    − Only use lines and fittings approved for use with the bioreactor or for which suitability has been confirmed in writing by Sartorius Stedim Biotech . − Only replace damaged components and worn parts with Sartorius Stedim Biotech approved parts .

  • Page 54: Connecting Network-Compatible Components To The Control Unit

    Getting Started 7.2.2 Connecting Network-Compatible Components to the Control Unit Connect components with a network connection to the “Fieldbus” port on the rear panel of the control unit . Modbus TCP-compatible components can be connected if their driver is supported by the DCU . Connecting the Supply Unit 7.3.1 Connecting the Supply Unit to the Control Unit...

  • Page 55: Connecting The Laboratory's Water Supply To The Supply Unit

    Getting Started 7.3.4 Connecting the Laboratory’s Water Supply to the Supply Unit ATTENTION Risk of injury due to bursting culture vessel! If the pressure in the temperature control circuit is too high, there is a risk that the double-walled versions of the culture vessels will burst . Ensure the correct connection of the cooling water inlet (1) and cooling water outlet (2) in the “Cooling Water”...

  • Page 56: Connecting Stirrer Drive

    Getting Started 7.3.6 Connecting Stirrer Drive CAUTION Risk of injury when motor is running! When detached, the motor can also be started up for testing by switching on the control unit of the DCU . Reaching into the running drive can cause injuries to the fingers .

  • Page 57: Connecting The Hoses For Aeration

    Getting Started Speed Ranges ATTENTION Depending on the size and equipment of the culture vessels, the permissible speed may be limited, e .g ., to max . 300 rpm in vessels with aeration rigs for bubble-free aeration . Operating the stirrer at impermissible high speeds can affect the culture vessel’s stability and cause damage to fittings .

  • Page 58: Connecting The Barcode Scanner

    Getting Started 7.3.9 Connecting the Barcode Scanner The calibration data is determined during production and delivered with the culture vessel for optical single-use pH and DO sensors . The pH and DO calibration data is located on the calibration sticker on the UniVessel ®...
  • Page 59 Getting Started Hose Kits Hose kits to connect double-walled culture vessels or the UniVessel ® SU heating/ cooling jacket are included with the equipment supplied . The exhaust coolers are supplied with the hose kits needed for connecting to the associated outlet of the supply unit .

  • Page 60: Heating Jacket

    Follow the associated safety instructions . The power consumption of the heating jacket used may not exceed 780 watts . Only use the parts specified by Sartorius Stedim Biotech . Special versions and especially models from other suppliers require the prior written agreement of Sartorius Stedim Biotech .
  • Page 61 Getting Started Heating Jacket Structure Fig . 7-5: Heating jacket Description Power cord Cable connection with overheating protection 6-pin Amphenol power cord Protective film of heating coil (vessel side) Heating coil Silicone foam sleeve Velcro fastener Connecting the Heating Jacket to the Supply Unit Ensure that the supply unit has been switched off at the “Mains I/O”...

  • Page 62: Connecting The Exhaust Cooling Hoses

    Getting Started Connecting the Exhaust Cooling Hoses Fig . 7-6: Hose kit, exhaust cooling for culture vessels Description Exhaust cooler Hose with sealing coupling for return Supply unit connection (return) Supply unit connection (inlet) Hose with sealing clip for inlet Connecting Hoses to the Supply Unit Connect the supply hose (5) to the supply unit connection (B) .

  • Page 63: Connecting The Balance

    Getting Started Connecting the Balance If a separate Sartorius balance is available or if a Cubis/Quintix/Secura balance is purchased later, the balance can be connected to the device: The weight unit of the balance matches the unit set in the DCU system (g or kg) and its measuring range .

  • Page 64: Switching The Control Unit And Supply Unit(S) On/Off

    Getting Started Switching the Control Unit and Supply Unit(s) On/Off The device must be properly installed and connected in accordance with the specifications . Ensure that all required energy supplies are connected to the supply unit(s) . Check whether all connections (cooling water and gas supply lines) and the signal cables for the supply unit, control unit, and to the culture vessels are connected .

  • Page 65: Preparing And Running The Process

    Preparing and Running the Process Preparing and Running the Process Overview Process preparation of the device during the relevant process includes the following main steps: − Equipping and changing the equipment of the culture vessels (see UniVessel Glass operating manual): ®...

  • Page 66: Connecting Transfer Lines

    Preparing and Running the Process Connecting Transfer Lines The transfer lines are connected between the correction medium bottle(s) and the culture vessel . Transfer Line for UniVessel Glass, UniVessel ® ® Standard Material Inner diameter Wall designation of the hose thickness 0 .8 x 1 .6;...

  • Page 67: Preparing The Cultivation Process

    Preparing and Running the Process Preparing the Cultivation Process CAUTION Danger of burns due to hot surfaces! The premature removal of culture vessels from the autoclave can cause burns . Let the culture vessels cool down inside the autoclave . Wear personal protective equipment .

  • Page 68: Mounting The Stirrer Drive

    Preparing and Running the Process 8.4.1 Mounting the Stirrer Drive CAUTION Risk of injury when motor is running! When detached, the motor can also be started up for testing by switching on the control unit of the DCU . Reaching into the running drive can cause injuries to the fingers . Do not reach into the sleeve with your fingers .
  • Page 69 Preparing and Running the Process Installing UniVessel Culture Vessels ® Fig . 8-1: UniVessel stirrer coupling ® Description Motor Sleeve Coupling Fastening screw CAUTION Danger of crushing when positioning the motor! There is a danger of crushing when placing the coupling onto the stirrer shaft . −...

  • Page 70: Installing The Heating/Cooling Jacket

    Preparing and Running the Process Installing UniVessel SU Culture Vessels ® It is not possible to fit the motor for the stirrer shaft directly to the coupling when using UniVessel SU culture vessels . An adapter is required in order to fit the motor . ®...

  • Page 71: Connecting The Aeration Modules

    Preparing and Running the Process 8.4.3 Connecting the Aeration Modules 8.4.3.1 Conducting Preliminary Steps The culture vessels must be fitted with the equipment needed for submerged aeration (see UniVessel Glass operating manual): ® − Sparger pipe with ring sparger or microsparger −...

  • Page 72: Connecting The "O

    Preparing and Running the Process 8.4.3.3 Connecting the “O Enrichment” and “Gasflow Ratio” Aeration Modules WARNING Danger of suffocation due to nitrogen during zero point calibration! Never leave the device unattended during zero point calibration . Connect the hose from the “Sparger” outlet (2) to the supply air filter of the culture vessel .

  • Page 73: Preparing The Corrective Medium Supply

    Preparing and Running the Process 8.4.4 Preparing the Corrective Medium Supply The supply unit can contain up to 8 WM114 peristaltic pumps for supplying correction media (acid, base, anti-foam agent, or nutrient solution) . Preliminary Steps: The culture vessels must be fitted with the following equipment needed for supplying correction media or media removal (see culture vessel operating manual): −...
  • Page 74 Preparing and Running the Process Changing the Position of the Hose Holder Changing to smaller hose diameter:  Prior to changing the hose holder position, turn off the pump . In order to re-position the lower hose holders on both sides of the pump head, use a pointed object (e .g ., a ballpoint pen) .
  • Page 75 Preparing and Running the Process Check if the hose holders on both sides of the pump head are set up according to the used hose size (see Chapter “Changing the Position of the Hose Holder”) . Lift up the cover completely . Make sure that there is sufficient hose available for the curvature inside the pump’s track .

  • Page 76: Performing A Process

    Preparing and Running the Process Performing a Process NOTICE Premature aging of the sensor patches in UniVessel ® Incoming light causes the optical sensors to age prematurely, if no culture vessel is placed on the UniVessel® SU during initialization . Do not initialize the UniVessel SU holder without a culture vessel in place .

  • Page 77: Alternating Operation Between Glass Culture Vessel And Univessel Su

    Preparing and Running the Process 8.5.3 Alternating Operation between Glass Culture Vessel and UniVessel ® The DCU system can be prepared for alternating operation between a glass culture vessel and UniVessel SU with a heating/cooling jacket . Upon delivery, the system’s ®...

  • Page 78: Main" Menu

    “Main” Menu “Main” Menu 8.6.1 General Information The “Main” menu opens after the control unit has been switched on . This is the central starting point for in-process operation . Fig . 8-1: “Main Overview All” screen for a 6-way system Fig .

  • Page 79: Process Displays In The "Main" Menu

    “Main” Menu 8.6.2 Process Displays in the “Main” Menu The function elements can display associated process values: − Values measured by connected probes such as pH, DO, foam, etc . − Calculated variables like pump filling amounts, calculated values of arithmetic functions, etc .
  • Page 80 “Main” Menu Setpoint configuration and mode selection for pumps, example “FLOW-#” Stirrer speed “STIRR-#” Pressure measurement, where necessary pressure control (if used) PRESS-# BIOSTAT ® B-DCU Operating Instructions...

  • Page 81: Trend" Menu

    “Trend” Menu “Trend” Menu 8.7.1 Trend Display The trend display provides a graphical view of the process value time profiles . The trend display gives, for example, a quick impression as to whether the process is running as expected or whether irregularities or disruptions are present . The trend display offers the following functions: −...

  • Page 82: Changing The Settings For A Channel

    “Trend” Menu 8.7.2 Changing the Settings for a Channel To change the configuration of a channel: Press the desired channel in the trend display, e .g ., Channel 4 “DO-# .” The “Channel # Settings” window opens . Fig . 8-2: “Channel # Settings” window Name Description 100 .0 sat%...

  • Page 83: Assigning A Process Value To A Channel

    “Trend” Menu 8.7.2.1 Assigning a Process Value to a Channel In the “Channel # Settings” window: Press the “PV” key . The “Select Buffered Channel” window appears, where a parameter can be assigned to a channel . To display all parameters in the configuration: Press “Cfg .” Fig .

  • Page 84: Calibration" Menu

    “Calibration” Menu “Calibration” Menu 8.8.1 General Information In the “Calibration” menu, all calibration actions required for routine operation can be activated: − Calibration routines for sensors: e .g ., pH, DO (pO ), turbidity − Sensor function test: e .g ., REDOX −...

  • Page 85: Group Or Single Calibration

    “Calibration” Menu 8.8.2 Group or Single Calibration When using multiple pH and DO (pO ) probes for parallel measurements, the calibration of the probes can be carried out as a single or a group calibration . Single calibration is described in detail in the following chapters . There is, in principle, no difference between group calibration and single calibration, so the process is not described in detail a second time .

  • Page 86: Ph Calibration (Conventional Sensor)

    “Calibration” Menu Fig . 8-5: Overview menu of all connected sensors (in this example, digital pH sensors) Detailed information on calibrating individual sensors can be found in the following chapters . 8.8.3 pH Calibration (Conventional Sensor) 8.8.3.1 General Information on pH Sensors Conventional pH sensors are calibrated using a two-point calibration with buffer solutions .

  • Page 87: Calibration Ph-#" Submenu

    “Calibration” Menu − The pH sensors must be serviced or replaced when the following values are outside the specified range*: − Zero point offset (“zero”) outside -30 to +30 mV − Slope is outside the range of 56 . . . 59 mV/pH . −...

  • Page 88: Performing Calibration

    “Calibration” Menu 8.8.3.3 Performing Calibration Depending on your choice, only the zero point (Calibrate Zero) and the slope (Calibrate Slope) is calibrated, or a full calibration (Calibrate) is carried out . Selecting/Entering Temperature Compensation Press the “Calibrate” key in the “Calibration pH-# Mode” submenu . Select the type of temperature compensation .

  • Page 89: Direct Input Of The Zero Offset And Slope

    “Calibration” Menu 8.8.3.4 Direct Input of the Zero Offset and Slope Zero Offset Press the “Zero” key in the “Calibration pH-#” submenu . In the input window “pH-#: Zero Buffer,” input the pH value . In the input window “pH-#: Zero Value,” input the measured value for the zero offset .

  • Page 90: Calibration Ph-B#" Submenu

    “Calibration” Menu 8.8.4.2 “Calibration pH-B#” Submenu The “Calibration pH-B#” submenu shows both the pH value and the measurement chain voltage of the sensors, as well as the zero offset (“zero”) and slope sensor parameters . That allows you to easily check the functionality of the pH sensors . Press the key for the sensor to be calibrated (“pH-B#”) in the “Calibration”...

  • Page 91: Performing Calibration

    “Calibration” Menu 8.8.4.3 Performing Calibration Depending on your choice, only the zero point (Calibrate Zero) and the slope (Calibrate Slope) is calibrated, or a full calibration (Calibrate) is carried out . Press the “Calibrate” key in the “Calibration pH-B# Mode” submenu . Zero Point Calibration The input window “pH-B#: Zero Buffer”...

  • Page 92: Direct Input Of The Slope

    “Calibration” Menu Wait for the slope calibration to take place (approx . 3 minutes) . Confirm the slope calibration with “ok .” The pH sensor is calibrated . 8.8.4.4 Direct Input of the Slope Press the “Slope” key in the “Calibration pH-B#” submenu . In the input window “pH-B#: Slope Buffer,”...
  • Page 93 “Calibration” Menu Wait for recalibration to take place . The DCU system calculates the zero offset and displays the corrected pH value . Confirm the recalibration with “ok .” The sensor status display may change after a recalibration if it differs too greatly from the initial calibration .

  • Page 94: Do (Po ) Calibration (Conventional Sensor)

    “Calibration” Menu 8.8.5 DO (pO ) Calibration (Conventional Sensor) 8.8.5.1 General Information on the DO (pO ) Sensors Calibration of the DO (pO ) sensor is based on a two-point calibration . Measurement is performed in “% oxygen saturation .” Calibration determines the sensor parameters zero current (“zero”) and slope (“slope”) .

  • Page 95: Performing Calibration

    “Calibration” Menu Press the “Measure” key in the “Calibration pO2-#” submenu . The “Calibration pO2-# Mode” submenu opens . 8.8.5.3 Performing Calibration Depending on your choice, only the zero point (Calibrate Zero) or the slope (Calibrate Slope) is calibrated, or a full calibration (Calibrate) is carried out . The DO (pO ) sensor must be serviced if: −...

  • Page 96: Direct Input Of The Zero Offset And Slope

    “Calibration” Menu Slope Calibration Slope calibration of the DO (pO ) sensor can be performed as follows: − on the laboratory table in the ambient air, − in medium gassed with air (as described in the following): Set the “AIR” aeration to 100%, all other aeration to 0% . Set the stirrer speed (STIRR) to approx .

  • Page 97: Calibration Po

    “Calibration” Menu 8.8.6.2 “Calibration pO -B#” Submenu In addition to DO (pO ) saturation, the “Calibration pO2-B#” submenu also shows the zero current and slope sensitivity with calibration conditions . This enables easy regulation of the sensor's functions . Press the key of the sensor to be calibrated (“pO2-B#”) in the “Calibration” menu . The “Calibration pO2-B#”...

  • Page 98: Performing Calibration

    “Calibration” Menu 8.8.6.3 Performing Calibration Depending on your choice, only the zero point (Calibrate Zero) or only the slope (Calibrate Slope) is calibrated, or a full calibration (Calibrate) is carried out . The DO (pO ) sensor must be serviced: −...
  • Page 99 “Calibration” Menu Slope Calibration Slope calibration of the DO (pO ) sensor can be performed as follows: − on the laboratory table in the ambient air, − in medium gassed with air (as described in the following): Set the “AIR” aeration to 100%, all other aeration to 0% . Set the stirrer speed (STIRR) to approx .

  • Page 100: Optical Ph And Do

    “Calibration” Menu 8.8.7 Optical pH and DO (pO ) Sensors Sartorius Stedim Biotech's optical sensor technology makes it possible to measure the pH and dissolved oxygen values non-invasively . The sensors are integrated into various systems . On the UniVessel ®...

  • Page 101: Notes On Calibration

    “Calibration” Menu Fig . 8-6: “Calibration 2” main menu with display of the optical probe signal quality 8.8.7.2 Notes on Calibration The indicator strip for the measured value sensors decays when exposed to light . The measured value drifts by approx . 0 .13 pH based on 10,000 measurements . To compensate for this drift, enhanced DCU configurations provide a “recalibration”...

  • Page 102: Calibration Ph-#" Submenu

    “Calibration” Menu It is recommended to recalibrate the pH sensors daily . A recalibration is also necessary if the ionic strength of the medium is changed by adding feed etc . 8.8.8.1 “Calibration pH-#” Submenu Field Value Function, input required Mode Display of the active operating mode: Measure, Calibrate, Recalibrate...

  • Page 103: Entering Initial Calibration Data

    “Calibration” Menu 8.8.8.2 Entering Initial Calibration Data The calibration data to be entered is printed on the UniVessel ® SU used . This data must be entered, as no (valid) pH measurement is possible beforehand . (When using the UniVessel SU, the calibration data can also be scanned in using the barcode ®...

  • Page 104: Performing Recalibration

    “Calibration” Menu Transferring the Parameters The data is transferred to the DCU system . Wait until the parameters have been transferred . The initial calibration of the pH sensor is now complete . 8.8.8.3 Performing Recalibration Press the “Inactive” key to open the “Calibration pH-# Mode” window . Press the “Re-Calibrate”...

  • Page 105: Configuring The Measurement Cycle For Ph Measurement

    “Calibration” Menu 8.8.8.4 Configuring the Measurement Cycle for pH Measurement Optical pH sensors show decay of the indicator dyes, e .g ., photo-bleaching . This degradation depends on the amount of light and increases with the pH value (for alkaline media) . The pH sensors used in culture bags are designed for 20,000 measurement points .

  • Page 106: Do (Po ) Calibration (Optical Sensor)

    “Calibration” Menu 8.8.9 DO (pO ) Calibration (Optical Sensor) To calibrate optical DO (pO ) sensors, proceed as follows: Enter the initial calibration data (see Chapter 8 .8 .9 .2, page 107) . Wait until the medium has reached the process temperature . Let the probes soak in the medium for at least 2 h .

  • Page 107: Performing Initial Calibration

    “Calibration” Menu 8.8.9.2 Performing Initial Calibration The calibration data to be entered is printed on the UniVessel ® SU used . This data must be entered, as no (valid) DO (pO ) measurement is possible beforehand . (When using the UniVessel SU, the calibration data can also be scanned in using the ®...

  • Page 108: Performing Recalibration

    “Calibration” Menu Transferring Parameters The data is transferred to the DCU system . Wait until the parameters have been transferred . The initial calibration of the DO (pO ) sensor is now complete . 8.8.9.3 Performing Recalibration Press the “Inactive” key to open the “Calibration pH-# Mode” window . Press the “Re-Calibrate”...

  • Page 109: Totalizer For Pumps And Valves

    “Calibration” Menu Change the value for the DO (pO ) measurement cycle according to the above calculation . Confirm the input with “OK .” 8.8.10 Totalizer for Pumps and Valves Function For documenting the correction medium consumption, the DCU system adds up the running times of the pumps or solenoid valves .
  • Page 110 “Calibration” Menu Hang the hose from the pump outlet into a measuring cup that you can use to measure the feed rate . The analog pumps must be controlled by the Subs controller . Activate the pump with “on .” Leave the pump activated until the hose is completely filled .

  • Page 111: Balance Taring

    “Calibration” Menu 8.8.11 Balance Taring Function The weight of culture vessels, feed bottles, or media and harvest containers can be measured on weighing platforms or pressure gauges . Any tare corrections required, e .g . after re-equipping the culture vessel or refilling a holding bottle, can be made during running operations .

  • Page 112: Redox Calibration

    “Calibration” Menu Changing the Tare Weight via Direct Entry Press the “Tare” key in the “VWEIGHT-#” submenu . In the “VWEIGHT-#: Tare” input window, input the new weight via the on-screen keypad . Confirm the weight change with “OK .” The “Tare”...

  • Page 113: Turbidity Calibration

    “Calibration” Menu 8.8.13 Turbidity Calibration Function Calibrating the turbidity measuring probe determines the electrode parameter “zero offset” by means of a one-point calibration . Taking the zero point deviation into account, the system calculates the turbidity value as a mean over a defined measuring time in absorption units (AU) and as a function of the damping factor .

  • Page 114: Setting The Speed Of The Internal Analog Pumps

    “Calibration” Menu 8.8.14 Setting the Speed of the Internal Analog Pumps The speed of the internal analog pumps can be changed . Note that changing the pump speed will affect other process parameters . Fig . 8-7: Setting the speed range of the internal analog pumps In the “Calibration”...

  • Page 115: Controller" Menu

    “Controller” Menu “Controller” Menu 8.9.1 Functional Principle and Equipment The control loops in the DCU system work as PID controllers, setpoint generators, or two-point controllers and are adapted to their control circuits . PID controllers can be parameterized to match the control task . The controller outputs control their actuators either continuously or using pulse-width modulation .

  • Page 116: Controller Selection

    “Controller” Menu Controller Mode You can switch between controller operating modes: Controller switched off with defined output Auto Controller activated Manual Manual access to actuator Profile Selection of previously defined profile . If no profile is defined, the controller automatically switches to “auto” mode 8.9.2 Controller Selection...

  • Page 117: Setpoint Profiles

    “Controller” Menu Field Display Function, input required Mode Controller and slave controller switched off Auto Controller switched on, slave controller in “Cascade” operating mode Manual Manual access to control output Profile Selection of previously defined profile . If no profile is defined, the controller automatically switches to “auto”...
  • Page 118 “Controller” Menu Accessing Screens Call up the appropriate controller . Press the “Profile Param .” key to open the following screen . Fig . 8-2: Screen using the example of the AIRSP profile Field Value Function, input required Add a profile spike Mode Setpoint profile not active Profile...

  • Page 119: General Controller Parameterization

    “Controller” Menu 8.9.5 General Controller Parameterization For optimum adaptation of the controller to each control segment, the controller parameters can be changed using the parameterization screens: Controller Parameterization Using the Example of a TEMP Controller Field Display Function, input required MIN, MAX Value in % Minimum and maximum output limit for the controller...

  • Page 120: Controller Parameterization Menu Screen

    “Controller” Menu 8.9.5.3 Controller Parameterization Menu Screen Field Value Function, input required Minimum output limitation, limit value for switch to upstream slave controller Maximum output limitation, limit value for switch to down- stream slave controller DEADB Dead zone in the unit of the process value P share (proportional range);...

  • Page 121: Guide And Slave Controller (Temp, Jtemp) Temperature

    “Controller” Menu 8.9.6 Guide and Slave Controller (TEMP, JTEMP) Temperature Measurement Temperature measurement with guide and slave controller is only possible in conjunction with double-walled vessels . The temperature control works like a cascaded regulation . The TEMP controller uses the temperature measured in the culture vessel as a master value and acts on the mode of the JTEMP slave controller .

  • Page 122: Speed Regulation (Stirr)

    “Controller” Menu − For routine operation, you only need to configure the master controller “TEMP-#” (setpoint, mode, and alarm limits) . − Direct configuration for heating and cooling can be done on the slave controller “JTEMP-#” when the master controller “TEMP-#” is turned off (“manual” mode) . −...
  • Page 123 “Controller” Menu Operation NOTICE High speeds can damage vessel attachments! Often only a certain maximum stirrer speed is allowed depending on the vessel type, volume, and equipment . Higher stirrer speeds can damage vessel attachments, e .g ., a hosed aeration system . Vessels can become unstable and move across the surface of the floor .

  • Page 124: Anti-Foam Controller (Foam)

    “Controller” Menu 8.9.8 Anti-foam Controller (FOAM) Function The autoclavable foam sensor is installed in the culture vessel . The sensor is adjustable in height, so that the sensor tip can be adjusted to the maximum level of the medium . A threshold signal generated by the foam sensor and amplified by a measurement amplifier serves as the input signal of the “Controller FOAM-#”...

  • Page 125: Level Control With Level Sensor (Level)

    “Controller” Menu 8.9.9 Level Control with Level Sensor (LEVEL) Function The autoclavable level sensor is installed in the culture vessel . The sensor is adjustable in height, so that the sensor tip can be adjusted to the maximum level of the medium .

  • Page 126: Adjusting The "Vweight" Gravimetric Level Controller

    “Controller” Menu 8.9.10 Adjusting the “VWEIGHT” Gravimetric Level Controller With gravimetric leveling, it is possible to maintain a particular medium volume in the culture vessel . The pump speed is controlled automatically depending on the weight change in the culture vessel . When the medium volume is regulated, there is a difference between: −...

  • Page 127: Adjusting The "Flow" Gravimetric Filling Pump Controller

    “Controller” Menu 8.9.11 Adjusting the “FLOW” Gravimetric Filling Pump Controller The gravimetric filling pump controller works with a weighing system and a variable speed filling pump . The controller works directly with the weight measured by the balance as an input signal, facilitating precise filling over days and weeks . The following information must be taken into account when adjusting the controller: −...

  • Page 128: Filling Pump Controller (Subs)

    “Controller” Menu 8.9.12 Filling Pump Controller (SUBS) Function To introduce nutrient solution, the filling pump controller can control an internal or external pump . The controller function works as a setpoint generator, handles control, and emits an analog setpoint signal for the pump . Controller Screens Operation Set the desired quantity to add via “Setpoint .”...

  • Page 129: Adjusting The Ph Controller

    “Controller” Menu − Note the specifications for the measurement/control range of the aeration rates of the device . With a device operated with overpressure, the counter pressure might cause the maximum aeration rate not to be reached . Procedure Configure the controller according to requirements, for example: Parameter Value Description Operating...
  • Page 130 “Controller” Menu Procedure Configure the controller according to requirements, for example: Parameter Value Description Operating Shows the operating mode selection window mode The pH controller is switched off . Slave controllers can be individually adjusted Auto Adjust and regulate the pH value using the “Setpoint”...
  • Page 131 “Controller” Menu Applicable Value Range of PID Parameters Parameter Unit Value 0 … 100 0 … 100 0 .1 . . . 1000 1 … 10,000 0 … 1000 Change the process value source Multiple, different pH sensors (conventional, optical) can be installed on the device . One of these sensors can be selected as the process value source for pH regulation .

  • Page 132: Regulation Methods

    “Controller” Menu 8.9.15 DO (pO ) Regulation Methods The DCU system features various methods of DO (pO ) regulation . The configuration and process being used determine which method is possible, required or sensible for the controlled end device . −...

  • Page 133: Adjusting The Do (Po ) Sensor Process Value Source

    “Controller” Menu 8.9.15.1 Adjusting the DO (pO ) Sensor Process Value Source The DO (pO ) controller must be set to the process value to be used for control with reference to the DO (pO ) sensor used . Types of DO (pO ) Sensors Description Type...

  • Page 134: Do (Po ) Controller Cascade (Cascade Controller)

    “Controller” Menu 8.9.15.2 DO (pO ) Controller CASCADE (Cascade Controller) Screen Fig . 8-4: DO (pO ) cascade controller menu on the “Controller – All” screen Refer to Chapter “8 .9 .3 General Controller Operation,” page 116 for notes on the fields, entered values, and entries . The screen also include the following input fields: Field Value...
  • Page 135 “Controller” Menu DO (pO ) Cascade Controller Parameterization Screen Fig . 8-5: Example: configuration of the screen Field Value Function, display, input required DEADB Input of the deadband Cascade # [Controllers] Slave controller with the relevant parameters Minimum output limit, corresponding to the minimum setpoint for the slave controller Maximum output limit, corresponding to the maximum setpoint for the slave controller...

  • Page 136: Do (Po ) Controller Advanced (Polygon Controller)

    “Controller” Menu Operation of the Multi-stage Cascade Controller Select the slave controller according to the desired priority in the “Cascade Parameter pO2-#” submenu . Set each minimum and maximum controller setpoint limit for the selected slave controller using the output limits MIN or MAX in the parameterization screen of the DO (pO ) controller .
  • Page 137 “Controller” Menu Screen Fig . 8-6: DO (pO ) controller menu on the “Controller – All” screen Settings for the Advanced DO (pO ) Controller Operating Display for the Master Controller Field Value Function, display, input required Mode Controller switched off, output on stand-by Auto Controller active, controls the actuator if necessary Manual...
  • Page 138 “Controller” Menu Example: Input (modification) of the DO (pO ) setpoint Since the selection of slave controller can be changed according to process requirements, the setpoint of the DO (pO ) controller output is set in % relative to the control range . The slave controllers control their actuators with setpoints in their physical units .
  • Page 139 “Controller” Menu Setting the “P,” “I,” or “D” Controller Parameters: The adaptation of PID controllers requires knowledge of control theory . The setting options listed here are rough guidelines . Only qualified personnel should carry out controller optimization . Depending on the process (e .g ., stability of gas intake or actuator), it may be necessary to change the parameters “P,”...
  • Page 140 “Controller” Menu Field Value Function, display, input required Setpoint Input of the setpoint for the master controller Mode Disable Manually switchable mode of the slave controllers Enable (only available when the master controller is in operating state “off” or “disabled”) Selecting Slave Controllers Activate “Cascade Param .”...
  • Page 141 “Controller” Menu Special Notes The slave controllers work as long as the master controller is active, that is, in “auto” or “manual” mode . After the master controller is turned off (in state “off”), the slave controllers can be operated manually, either individually or together in the selected combination .
  • Page 142 “Controller” Menu Example for “O Enrichment” Aeration Strategy (Air, O In the “O Enrichment” aeration strategy, air is first used for the enrichment of the medium . If this is not sufficient, the air is then continuously enriched with pure oxygen in order to ensure a sufficiently high content of oxygen in the medium .

  • Page 143: Using Pumps From Ph, Foam, And Level Control For

    “Controller” Menu Example for “Gasflow Ratio” Aeration Strategy (Air, O In the “Gasflow Ratio” aeration strategy, a constant amount of gases is supplied to the culture vessel . Select “AIRSP-1” and “O2SP” as slave controllers . For “AIRSP-1,” set − a maximum setpoint for “Out” = 0% −...
  • Page 144 “Controller” Menu Fig . 8-10: Deactivating the anti-foam controller output Change the “AFOAM-#” controller output on the “Output AFOAM-#” controller screen to “NONE .” Fig . 8-11: Activating the output of the SUBS-G# substrate controller Open the “SUBS-G#” controller screen . Open the controller parameters .

  • Page 145: Glucose Controller (Gluco)

    “Controller” Menu 8.9.17 Glucose Controller (GLUCO) Function The glucose controller controls the addition of glucose in the culture vessel, so that the glucose concentration in the culture is maintained at a constant level . The measured value calculated by the BioPAT ®...

  • Page 146: Settings" Menu

    “Settings” Menu 8.10 “Settings” Menu NOTICE Danger of malfunctions and unsafe operating states due to impermissible settings. The “Settings” main function permits changes to the system configuration . Malfunctions that have unforeseeable impacts on safe operation can result from settings that are not permissible or are unsuited for a certain end device . Settings that impact safe operation are password-protected .

  • Page 147: Changing System Settings

    “Settings” Menu Functions Available for Selection Function System parameters Change system settings PV ranges Configure measuring ranges for process values Manual operation Manual operation: Switch process inputs and outputs manually External View status of externally connected devices, e .g ., balances Service Service and diagnostic access (for Sartorius Service only) Displayed System Information...

  • Page 148: Measuring Range Settings

    “Settings” Menu Changes to the date and time will only take effect in the first 5 minutes after the control unit is turned on . 8.10.3 Measuring Range Settings Required Qualification: Operating engineer | laboratory manager The beginning and end of the measuring range (“Process Value Ranges”) for all process values can be changed in the “Settings”...

  • Page 149: Manual Operation

    “Settings” Menu 8.10.4 Manual Operation Required Qualification: Operating engineer | laboratory manager When starting up operations and troubleshooting, all analog and digital process inputs and outputs as well as DCU internal inputs and outputs can be switched to manual operation (“Manual Operation”) . −...
  • Page 150 “Settings” Menu Screen Fig . 8-3: Manual configuration of digital inputs, example “HEATC” (simulation for signal of the power-on status of the heating) Field Value Function, display, entry required Description Display of the digital input, entry for “AUTO” or “MANUAL ON/OFF” operating mode Port Hardware address VALUE...

  • Page 151: Manual Operation For Digital Outputs

    “Settings” Menu 8.10.4.2 Manual Operation for Digital Outputs During manual operation, disconnect the digital output from the internal DCU function and manipulate it directly . For static digital outputs, e .g ., controlling valves, switch the output on or off . For pulse-width modulated outputs, manually enter the switch-on ratio in [%] .

  • Page 152: Manual Operation For Analog Inputs

    “Settings” Menu Field Value Function, display, entry required VALUE Digital output switched off Digital output switched on Switch-on ratio (0 . . . 100%) for pulse-width modulated digital outputs Special Notes: − The following signal levels apply to the switch status (status): OFF : 24 V for process outputs (DOP, DO) −...

  • Page 153: Manual Operation Of Analog Outputs

    “Settings” Menu Field Value Function, display, entry required Unit Physical variable Special Notes: − For internal analog inputs (AIM), the physical signal level is always 0 . . .10 V (0 . . .100%) − For external analog inputs (AIP), the signal level can be configured between: −...

  • Page 154: Manual Operation For Controllers ("Control Loops")

    “Settings” Menu Field Value Function, display, entry required Upstream function CL = controller expr = logical function – = without nn % | off Upstream controller output Display of output value: -100% . . . +100% Special Notes: − The physical signal level of the analog outputs (AO) can be configured between: −...

  • Page 155: Manual Operation Of Sequence Control ("Phases")

    “Settings” Menu Display of active cascade 0 = no cascade 1 . . . n = specific cascade for cascade controller Calculated output value Special Notes After working on the manual level, you have to switch all outlets back to the “AUTO” operating mode .

  • Page 156: Externally Connected Devices

    “Settings” Menu 8.10.6 Externally Connected Devices The “External” main function can be used to view and set the status of externally connected devices (e .g ., balances) . Only personnel authorized to do so may change the menu settings . To define settings in the menu, the standard password needs to be entered .

  • Page 157: Cleaning And Maintenance

    Cleaning and Maintenance Cleaning and Maintenance Incorrect cleaning and maintenance can lead to erroneous process results, causing high production costs . Regular cleaning and maintenance is thus essential . Among other factors, the operational safety and effective performance of fermentation also depend on proper cleaning and maintenance .

  • Page 158: Cleaning The Device

    The internal modules of the device, especially the safety devices, peristaltic pumps, drive motors, and stirrer shaft couplings, must only be serviced by Sartorius Service . Please return the device to Sartorius Stedim Biotech if it is defective . Observe the instructions for decontamination .

  • Page 159: Maintenance Schedule

    Cleaning and Maintenance 9.2.2 Maintenance Schedule The cyclical maintenance of the device depends on its service life . The following table lists the maintenance intervals as they are assigned to the components: Before every process After 10-20 autoclave cycles If unsterile Component Activity 1 + yearly...

  • Page 160: Carrying Out Maintenance Work On Safety Components

    Cleaning and Maintenance Before every process After 10-20 autoclave cycles If unsterile Component Activity 1 + yearly Membrane body, electrolyte Visual inspection, (Clark probes) replace if needed Sensor cap (optical O probe) Calibration, visual inspection Foam | level probe for damage Calibration, visual inspection Temperature probes for damage...

  • Page 161: Faults

    Faults 10 Faults 10.1 Procedure Always proceed according to the following steps when faults occur on the unit . Switch off the device . If the fault (e .g ., smoke or odors, abnormally high surface temperatures) represents a direct danger to personnel or property: Disconnect the device from the power supply (see Chapter 2 .7, page 13) .

  • Page 162: Counter Cooling System" Troubleshooting Table

    Faults Contamination Potential causes Corrective measures During the process Supply air filter or Check the filter and replace (rapid) connection has become if necessary . non-sterile or defective . Replace the connection line . Accidental or Take organizational measures unauthorized at the work site to prevent manipulation of the equipment from being...

  • Page 163: Process-Related Faults/Alarms

    Faults Problem Potential causes Corrective measures Air inlet line blocked Air inlet filter blocked . Check the air feed (dry and free of oil and dust) . If necessary, install a pre-filter . The gas or air supply Hose kinked or Check the hose and filter and, is blocked or disconnected .

  • Page 164: Alarm Overview" Menu

    Faults 10.3.2 “Alarm Overview” Menu The alarm overview can be selected as follows: Press the “Alarm” main function key . “Alarm” Screen Fig . 10-2: Alarm table, accessible through the “Alarm” function key Function, input required ACK ALL Acknowledges all activated alarms Acknowledges the selected alarm Resets and deletes the selected alarm 10.3.3 Process Value Alarms...
  • Page 165 Faults “Process Value Alarms” Screen Fig . 10-3: Submenu for configuring alarm monitoring, example “TEMP-1,” called from the “Controller” menu, overview “All” Field Value Function, input required High limit °C Upper alarm limit in the physical unit of the PV Low limit °C Lower alarm limit in the physical unit of the PV...

  • Page 166: Alarms For Digital Inputs

    Faults Screen Example: Exceeding the Alarm Limit Fig . 10-4: Alarm message, exceeding the alarm limit for pH-1 . − The alarm window closes after acknowledgment of the alarm with “Acknowledge” or after pressing [X] . − After the alarm is acknowledged with “Acknowledge,” the alarm symbol disappears .
  • Page 167 Faults “Alarm Monitoring” Screen Fig . 10-5: Activating and deactivating alarm monitoring <- -> Fig . 10-6: 19-6: Alarm deactivated, alarm activated Field Value Function, input required Alarms Param . Alarm monitoring operating mode Disabled Alarm monitoring locked for the input Enabled Alarm monitoring activated for the input Operating Notes...

  • Page 168: Alarms, Meaning, And Corrective Measures

    Faults 10.3.5 Alarms, Meaning, and Corrective Measures 10.3.5.1 Process Alarms The user can switch the individual alarms listed in the following table on and off: Text in the alarm line Description Remedy “Name” State Alarm Digital input alarm Confirm alarm with “ACK” key “Name”...

  • Page 169: Disposal

    Disposal 11 Disposal 11.1 General Information Packaging The packaging is made of environmentally friendly materials that can be used as secondary raw materials . If the packaging is no longer needed, it can be disposed of by local waste disposal authorities . Device The equipment, including accessories and empty non-rechargeable and rechargeable batteries, does not belong in your regular household waste;...

  • Page 170: Decommissioning The Device

    Disposal Decontamination Declaration Sartorius Stedim Biotech has a duty to protect its staff from hazardous substances . When returning devices and device components, the sender must enclose a decontamination declaration as proof of compliance with the safety regulations governing the area of application for which the devices were used .

  • Page 171: Dismantling The Device

    Disposal 11.4 Dismantling the Device WARNING Danger of severe injury due to ejected or falling parts! When disassembling the unit, pay particular attention to those components that contain parts under mechanical tension that could spring out during scrapping, leading to injury . There is also danger due to moving parts and falling objects . −...

  • Page 172: Storage And Shipping

    Storage and Shipping 12 Storage and Shipping 12.1 Storage Upon Delivery (Temporary Storage) Observe the transport conditions for the device (see Chapter “13 .7 Ambient Conditions,” page 176) . After Use Decommission the device (see Chapter 11 .3, page 170) . If required: Pack the device (see Chapter 12 .3, page 172) .

  • Page 173: Technical Specifications

    Technical Specifications 13 Technical Specifications 13.1 Control Unit 13.1.1 Dimensions Unit Value Depth Width Height Weight, approx . 13.1.2 Mains connection Unit Value Voltage 120/230 V (±10%) Frequency 60/50 Power consumption Protection IP30 13.2 Supply Unit 13.2.1 Dimensions Unit Value Depth Width Height...

  • Page 174: Work Surface For 6 Supply Units

    Technical Specifications Unit Value Protection class as per DIN EN 60529 IP20 13.2.4 Work Surface for 6 Supply Units Unit Value Depth Width 3300 13.3 Energy Connections Inside the Laboratory 13.3.1 Cooling Water Supply/Cooling Circuit Unit Value Flow rate, max . l/min Water pressure, max .

  • Page 175: Temperatures In The Univessel

    Technical Specifications 13.4 Temperatures in the UniVessel ® Unit Value Operating temperatures, max . °C + 80 Operating temperature, min . °C 13.5 Stirrer Drive Motor 200 W UniVessel Glass UniVessel Glass UniVessel ® ® ® direct coupling magnetic coupling Volumes [L] Speed range [rpm] 20-2000...

  • Page 176: Ambient Conditions

    Technical Specifications 13.7 Ambient Conditions Unit Value Installation location Conventional laboratory rooms, max . 2,000 m above sea level Ambient temperatures in the °C +5 to 40 operating temperature range Relative humidity < 80% for temperatures up to 31°C decreasing linearly < 50% at 40°C Impurities Pollution level 2 (Normally only non-conductive pollution...

  • Page 177: Dimensions Of The Variable Area Flow Meters

    Technical Specifications 13.9 Dimensions of the Variable Area Flow Meters The built-in variable area flow meters and mass flow controllers are calibrated to the following standard conditions . Calibration parameters Gas type Temperature 20° C = 293 K Pressure 1 .21 bar (absolute) When gases with deviating pressures pass through, higher or lower values can be displayed .

  • Page 178: Conformity & Licenses

    Conformity & Licenses 14 Conformity & Licenses 14.1 GNU Licensing DCU systems contain software subject to the license terms of the “GNU General Public License (GPL)” or the “GNU LESSER General Public License (LGPL) .” If applicable, the licensing terms and conditions of the GPL and LGPL as well as information about the options for access to GPL code and LGPL code used in this product are available upon request .
  • Page 179 Conformity & Licenses BIOSTAT ® B-DCU Operating Instructions...
  • Page 180 Conformity & Licenses BIOSTAT ® B-DCU Operating Instructions...
  • Page 181 Conformity & Licenses BIOSTAT ® B-DCU Operating Instructions...

  • Page 182: Appendix

    Appendix 15 Appendix 15.1 Pin Assignment Female Connectors X202 - “Serial-A” X203 - “Serial-B” DCD (in) RXD (in) TXD (out) DTR (out) RTS (out) CTS (in) M12 | Female Depending on the ordered configuration, a cable for connection of external components is supplied .
  • Page 183 Appendix X212 - “Power Out” Signal 24VDC 24VDC GND24V 24VDC GND24V SHIELD M12 | Female X210 - “Ext. Signals-A/B” X211 - “Ext. Signals-C/D” X213 - “Ext. Signals-E/F” Signal Color-coding of supplied cable EXT-A/C/E (white) GND EXT-A/C/E (brown) EXT-B/D/F (green) GND EXT-B/D/F (yellow) (gray) (pink)

  • Page 184: Decontamination Declaration

    Appendix X220 - “Pump-A” X221 - “Pump-B” X222 - “Pump-C” X223 - “Pump-D” Signal GND PUMP-A . . .D PUMP-A . . .D SHIELD M12 | Female X23 - “Common Alarm” Signal COMAL, NO (Normally Open) COMAL, COM COMAL, NC (Normally Closed) M12 | Female 15.2 Decontamination Declaration When returning equipment, use the following form:...
  • Page 185 Appendix Decontamination Declaration Declaration Concerning the Decontamination and Cleaning of Equipment and Components To protect our personnel, we require that all equipment or components which come into contact with our personnel at customers’ facilities be free of biological, chemical, or radioactive contaminants. We will only accept an order when: −...
  • Page 186 Sartorius Stedim Biotech GmbH August-Spindler-Strasse 11 37079 Goettingen, Germany Phone: +49.551.308.0 www.sartorius.com The information and figures contained in these instructions correspond to the version date specified below. Sartorius reserves the right to make changes to the technology, features, specifications and design of the equipment without notice.

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