NEW BRUNSWICK SCIENTIFIC BioFlo 4500 Manual To Operations Download Page 1

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BioFlo 4500

Benchtop

Fermentor/Bioreactor

MANUAL

NO:

M1254-0050

Revision H

September 27, 2002

NEW BRUNSWICK SCIENTIFIC CO., INC.

BOX 4005

•

44 TALMADGE ROAD

•

EDISON, NJ 08818-4005

Telephone: 1-732-287-1200

•

1-800-631-5417

Fax: 732-287-4222

•

Telex: 4753012 NBSCO

Internet: http://www.nbsc.com

•

E-mail: [email protected]

Summary of Contents for BioFlo 4500

Page 1: ...NO M1254 0050 Revision H September 27 2002 NEW BRUNSWICK SCIENTIFIC CO INC BOX 4005 44 TALMADGE ROAD EDISON NJ 08818 4005 Telephone 1 732 287 1200 1 800 631 5417 Fax 732 287 4222 Telex 4753012 NBSCO I...

Page 2: ...BioFlo 4500 M1254 0050 User s Guide ii...

Page 3: ...fic SARL 3 rue des Deux Boules 75001 Paris France Tel 33 0 1 4026 2246 Fax 33 0 1 4026 5423 E mail sales nbssarl fr GERMANY New Brunswick Scientific GmbH In Der Au 14 D 72622 N rtingen Deutschland Tel...

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Page 5: ...d personal injury can occur Please read the entire User s Guide before attempting to use this unit Do not use this equipment in a hazardous atmosphere or with hazardous materials for which the equipme...

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Page 7: ...es the right to change information in this document without notice Updates to information in this document reflect our commitment to continuing product development and improvement Manual Conventions N...

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Page 9: ...mbly and our obligation under this warranty is limited to repairing or replacing the instrument or part thereof which shall with in 1 year after date of shipment prove to be defective after our examin...

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Page 11: ...record the information for your Fermentor Bioreactor and retain this for future reference Model Number Voltage Serial Number Controller Type The above information can be found on the electrical specif...

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Page 13: ...essel Upper Side Wall Equipment 31 2 2 5 Standard Lower Side Wall 31 2 2 6 Optional Lower Side Wall Equipment 31 2 2 7 Vessel Bottom 32 2 3 PROCESS PIPING COMPONENTS 32 3 INSPECTION VERIFICATION UNPAC...

Page 14: ...63 8 ML 6100 CONTROLLER CONFIGURATION 65 8 1 CONFIGURING THE CONTROLLER 65 8 2 SYSTEM INFORMATION 66 8 3 CONTROL MODE SELECTION AND NODE NUMBER 67 8 4 PASSWORDING AND LOCKING 69 8 5 SCREENSAVER OPTIO...

Page 15: ...CONTROL SYSTEM WITH PERISTALTIC PUMP 115 15 2 SETUP OF FOAM PROBE 116 15 3 HIGH FOAM SAFETY SYSTEM 117 15 4 PUMP 3 ANTIFOAM SETUP 120 15 5 CONDUCTANCE PROBE CALIBRATION 121 15 6 CONDUCTANCE PROBE GROU...

Page 16: ...5 ML 6100 DEADBAND FEATURE 161 26 ML 6100 USE WITH BIOCOMMAND 163 27 PREPARING FOR ML 6100 CONTROLLED FERMENTATION 165 27 1 SYSTEMS CHECK 165 27 2 ADDING MEDIA TO THE VESSEL 166 27 3 STERILIZATION OF...

Page 17: ...97 34 3 THREE MONTH INTERVALS 197 34 4 ONE YEAR INTERVALS 198 34 5 AIR FILTER INLET EXHAUST 199 34 6 BATTERY REPLACEMENT 200 34 7 MOTOR REMOVAL 201 34 8 MOTOR INSTALLATION 202 35 TROUBLESHOOTING 203 3...

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Page 19: ...d harvested shut down Aseptic addition of culture medium and inoculum as well as aseptic sampling may be accomplished by the use of the steam sterilizable inoculation and sampling ports The BioFlo 450...

Page 20: ...on in place SIP of vessel and all process related components Embedded NBS ML 6100 multi loop process controller or third party SCADA system All related process components and piping are manufactured f...

Page 21: ...m kit 19mm diaphragm septum addition ports Re sterilizable poppet type inoculation addition valves Syringe septum addition assemblies Re sterilizable variable flow sample valve Auxiliary pump fixed sp...

Page 22: ...sh Dimensions 20L 9 48 ID X 18 81 H 24 08 cm ID X 47 48 cm H 30L 10 79 ID X 22 H 27 40 cm ID X 55 88 cm H Viewing Window Rectangular approx 1 W X 8 H 3 18 cm W X 21 6 cm H above and below maximum work...

Page 23: ...steel ASME coded piped to the bottom of console to drain Air Gas Overlay 19 mm Upper Side Wall Optional plugged as standard Inoculation Addition Port Ingold Type 19 mm ID Upper Side Wall Plugged as s...

Page 24: ...ssel 675W in 20L vessel 850W in 30L vessel Cooling water is admitted into the jacket through the temperature control valve and the flow control valve Control Mode PID with constants factory set at P 3...

Page 25: ...idity must be less than 95 for air and O2 2 Gas Mix Optional Control Mode Two solenoid valves in PWM Mode Manual control or oxygen enrichment Display Current composition of gas mixture displayed on to...

Page 26: ...r Peristaltic pump Control Mode Output type PWM 0 100 Mode On Off with Reverse action Display Current value setpoint controller output displayed on virtual display gauge at touchscreen BioFlo 4500 Gen...

Page 27: ...issue of ASME Sect VIII Pressure Vessel Code It is supplied with copies of the Manufacturer s Data Report U 3 The vessel includes the ASME Code Stamp Figure 1 Vessel Front View The bottom harvest drai...

Page 28: ...ressure relief valve There are four cartridge heaters 675W in the 20L vessel 850W in the 30L vessel at the bottom of the jacket not shown These are used to heat the vessel to the required growth tempe...

Page 29: ...ensity lamp Seven 28 mm threaded ports 19 mm ID plugged as standard Exhaust condenser port plugged as standard Bearing housing with single or optional double mechanical seal Rupture disK stainless ste...

Page 30: ...inge Septum cover and septum for 28 mm ports 2 2 3 Standard Vessel Upper Side Wall Air Gas Overlay plugged as standard Four 19 mm inoculation addition ports plugged as standard Rectangular viewing win...

Page 31: ...or Two 19 mm Ingold type ports one for optional sampling valve plugged as standard Three 25 mm Ingold type ports plugged as standard for spare and or optional pH or DO sensors Jacket water in Figure 5...

Page 32: ...harvest drain valve with 1 4 quick connect fitting 2 3 Process Piping Components All process piping valves and associated components are of type 316L stainless steel All other piping is of type 316L...

Page 33: ...he correct materials 3 3 Physical Location The surface on which you place the BioFlo 4500 Fermentor Bioreactor should be smooth level and sturdy Ensure that support structure and surface can bear the...

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Page 35: ...ance and that the surface can handle the weight of the unit including vessel contents and any auxiliary equipment The unit is shipped with the vessel attached and secured with three bolts that are acc...

Page 36: ...npack the computer and touchscreen monitor Save all packaging 2 Place the computer on a sturdy level surface in close proximity to the intended location of the fermentor 3 Place the touchscreen monito...

Page 37: ...ng below Figure 8 Touchscreen Connections 7 Attach the power cord to the monitor 8 Connect the 25 pin end of EXTERNAL COMPUTER CABLE to a suitable com port on the computer The electrical connections t...

Page 38: ...the EXTERNAL COMPUTER CONNECTOR on the rear panel of the console and connect the cable to the port Secure the cable by hand tightening the threaded cable seal Connect the other end of EXTERNAL COMPUTE...

Page 39: ...lied when an alarm condition occurs When the alarm is either disabled or acknowledged the controller will return the relay contact to its original position 4 5 BioCommand Connections A 25 pin BIOCOMMA...

Page 40: ...controller and can be integrated into the system as control loops The connections to these inputs are as follows Pin 1 Pin 2 Pin 3 Ground Figure 11 External Analog Inputs NOTE The J designations refer...

Page 41: ...external pump This fourth pump is controlled to turn on and off depending on system conditions The supply voltage for this pump is supplied by a line cord connected to the AC POWER IN RECEPTACLE The p...

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Page 43: ...ed before securing the headplate to the vessel The impellers are adjustable along the length of the shaft and are secured to the impeller by a locking collar Proper positioning of the impellers on the...

Page 44: ...the wingnuts Unbolt the headplate and remove Exercise caution when removing the headplate because the shaft is attached Lift the headplate with attached shaft straight up The baffles may also be remo...

Page 45: ...tioning it onto the bearing housing 5 Secure the motor using the four bolts provided connect the motor power cable to the AGITATION MOTOR CONNECTOR on the side of the console Wrench tighten but do not...

Page 46: ...the BioFlo 4500 become familiar with each service connection and its location The following table describes each service connection The BioFlo 4500 must be connected to regulated utilities as describ...

Page 47: ...vironment 1 4 FNPT Notes 1 For steam we recommend adding the steam prefilter regulator kit PN M1117 2020 2 Piping should be as short as possible and large in diameter to prevent excessive backpressure...

Page 48: ...particulates and oil If the air is laden with particulates and or oil an air prefilter regulator kit PN M1117 2020 is recommended Figure 16 Service Connections For gas connections see Figure 17 on the...

Page 49: ...ck Scientific Co Inc User s Guide 49 Figure 17 Gas Connections CAUTION Power fluctuations varying more than 10 from the nameplate rating can result in severe damage to the fermentor bioreactor electro...

Page 50: ...p leg with a steam trap be installed in the steam line as close as possible to the steam service connection This will prevent steam condensate from collecting in the line 5 5 2 Pure Steam Pure steam o...

Page 51: ...supply voltage matches the specified voltage and power requirements on the electrical specification plate located on the side panel of the fermentor console Because power fluctuations greater than 10...

Page 52: ...euse of the water Alternatively a closed loop water system including a chiller can be set up Refer to your local NBS parts distributor or sales office for chillers 5 6 Prefilter Regulator Kits Optiona...

Page 53: ...L 6100 controller skip ahead to Section 6 4 6 1 Initial Preparation 1 Turn the power on by setting main power switch on the side of the console to the ON position Figure 18 Console Side Panel 2 Adjust...

Page 54: ...into the THERMOWELL using an eyedropper or transfer pipette 2 Verify that the RTD TEMPERATURE PROBE is connected to the console insert the probe into the THERMOWELL and secure it 3 Verify that the te...

Page 55: ...is turned on 2 The START UP screen will appear on the monitor The message Please wait while communications are established with the control hardware will be in a window in the middle of the display 3...

Page 56: ...to touch the monitor in two locations and press OK to exit the touchscreen calibration utility 6 4 Harvest Drain Valve The BioFlo 4500 is equipped with a manually operated re sterilizable plunger type...

Page 57: ...h the valve for about 15 minutes 4 Close the STEAM INLET VALVE 5 Allow the valve to cool thoroughly before using To harvest drain the vessel aseptically choose one of the following two methods 6 4 1 A...

Page 58: ...out the liquid from inside the vessel 6 After draining the vessel close the drain valve by rotating the drain valve 180 In the closed position the handle should be facing the front panel console and t...

Page 59: ...drain rotate the drain valve handle as far as it will allow so it is facing the front of the vessel When the valve is open the word OPEN is visible on the end of the handle 10 Draining of the liquid m...

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Page 61: ...POWER SWITCH on the fermentor bioreactor Turn on the computer and touchscreen monitor if applicable to your system If your system includes an external computer the BioFlo 4500 will not communicate wit...

Page 62: ...has been deleted or if there is no current controller configuration All BioFlo 4500 fermentor bioreactors are pre configured at the factory for all standard process parameters and any factory installe...

Page 63: ...he user access to the Change Loop Settings Window CURRENT VALUE Displays the current value of the loop as a numerical value and a bar graph CONTROL MODE The selected method of control for the loop If...

Page 64: ...e control mode press the one you want to select NOTE If you are unfamiliar with control modes see Section 9 ML 6100 Control Loop Operations Press the values you wish to use If a negative sign is desir...

Page 65: ...ecifying for each controlled parameter its display input output and control characteristics It also includes identifying the terminals used to connect the input from the loop sensor probe tachometer e...

Page 66: ...e will appear asking if you want to change the control type If you do press the YES BUTTON If not press the NO BUTTON 8 2 System Information To view system information specific to your controller pres...

Page 67: ...MODE To set or change any of these components From the MAIN CONFIGURATION SCREEN press the MODE or NODE NUMBER text boxes Touching either box will display the LOCAL CONTROL SETUP WINDOW The LOCAL CON...

Page 68: ...ppear on the buttons When SHIFT is written in red uppercase letters and a different character set appear on the buttons To clear the text box press the CLEAR BUTTON To accept the text in the text box...

Page 69: ...such as process loop setpoint changes The second level of security is designed to safeguard the configuration of the controller and the process loops The Controller Interface Software accepts a differ...

Page 70: ...OK To cancel press CANCEL If you wish to change the SYSTEM CONFIGURATION PASSWORD select it by touching the white circle next to it To change either password 1 Choose the password you wish to change a...

Page 71: ...k value the prompt will not appear 4 The lock icon on the LOCK BUTTON will change from unlocked to locked compare sample button above which is unlocked to sample button below which is locked To exit t...

Page 72: ...er option is disabled If you wish to have a screensaver when using the controller you must enable the screensaver as follows 1 Press the CONFIG BUTTON in the GAUGE SCREEN 2 In the MAIN CONFIGURATION S...

Page 73: ...ler communicate with BioCommand For example if your application requires 16 control loops on the controller only the first ten configured control loops will be available in BioCommand This limitation...

Page 74: ...added To add the loop press OK 9 To leave the MAIN CONFIGURATION SCREEN press the CLOSE BUTTON A DISPLAY GAUGE will appear in the GAUGE SCREEN with the loop name that was just added 9 2 Configuring Co...

Page 75: ...e and setpoint touch the SETPOINT ICON The LOOP SETPOINT MODE SCREEN will appear 7 Select either LOCAL or ANALOG for the LOOP CONTROL MODE LOCAL will allow the ML 6100 controller to directly control t...

Page 76: ...The SELECT INPUT DEVICE SCREEN will appear 10 Select the INPUT TYPE and CONNECTOR ID by pressing on the selections you wish to use The CONNECTOR ID WINDOW will only display available inputs If an inp...

Page 77: ...Proportional Integral and Derivative error components Enter P I and D values MANUAL Controller output is set by user between 0 and 100 of maximum output ON OFF Controller output toggles between fully...

Page 78: ...Refer to the Controlling Mixing Addition Gases section of this manual for details NOTE For Frequency and Tachometer Wheel inputs the integral will not run if the feedback signal is zero To compensate...

Page 79: ...itional digital controller output which is OFF when either controller output or setpoint is zero ON when both setpoint and controller output are not zero This function is used to actuate the shutdown...

Page 80: ...N The SELECT OUTPUT DEVICE SCREEN will appear 23 Choose the OUTPUT TYPE Refer to the output device manufacturer s specifications The CONNECTOR ID WINDOW will indicate which terminals are used to conne...

Page 81: ...the CONFIG BUTTON in the GAUGE SCREEN The configuration screen will appear 2 Select a control loop from the loops list and press the DELETE BUTTON You will be prompted to enter the SYSTEM CONFIGURATI...

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Page 83: ...to the media in the inner vessel Cooling water is admitted to the jacket through the temperature control valve and the flow control valve Vessel temperature control during the growth cycle is control...

Page 84: ...ype PWM 0 100 PWM Period 10 Gains P 30 I 1 D 0 Norm Const 100 Limits High 125 Low 0 Mode Local Conn N A Type N A From N A Gain N A Offset N A Controller Loop Name Temp Sterilization Output Device Outp...

Page 85: ...hton turbine impellers are mounted on the impeller shaft as standard Impellers are removable and adjustable along the length of the shaft The impellers are sized to be capable of producing a minimum o...

Page 86: ...on To operate the agitation control system 1 Ensure that the main power switch is ON and that there is power to the fermentor 2 Set the agitation control loop on the touchscreen to PID control NOTE Op...

Page 87: ...Offset N A Controller Loop Name Agit Sterilization Output Device Output Device B Output Device A Conn N A Type N A Conn S1 J5 7 8 Type Iso V mA Recorder Conn S1 TR1 RE1 Type Frequency Scaling Linear...

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Page 89: ...filter and is mounted in a 316L stainless steel housing Domnick Hunter or other brand name filters can be supplied upon request All piping valves and fittings in the air system are fabricated of 316L...

Page 90: ...g Linear Filter Gain 1 00 Filter Band 0 Meas Limits N A Enabled No Conn N A Type N A 12 1 Vessel Pressure MANUAL PRESSURE CONTROL Manual pressure regulation is achieved with an in line pressure gauge...

Page 91: ...Controller Loop Name PRt35 Sterilization Output Device Output Device B Output Device A Conn N A Type N A Conn S1 J5 1 2 Type None Recorder Conn S2 J6 33 34 Type 4 20 mA Scaling Linear Filter Gain 1 Fi...

Page 92: ...gas then enters a stainless steel heat exchanger that heats the exhaust gas above its dew point Next the gas enters a steam sterilizable depth optional 0 2 absolute filter which is installed to contin...

Page 93: ...extended valve life Special Note for Four Gas Applications In systems equipped with four gas control two thermal mass flow controllers have been provided When fermentation is the primary task the con...

Page 94: ...nitrogen and carbon dioxide as required to control DO and pH A constant gas flow rate is maintained during this process The composition of the gas mixture is determined by the duty cycle of the solen...

Page 95: ...id Valve Output Device Conn S5 Txo 1 8 Output Device Conn S5 Txo 9 16 CO2 1 2 9 10 Nitrogen 3 4 11 12 Oxygen 5 6 13 14 Air 7 8 15 16 SSR Gas 1 CO2 2 Nitrogen 3 Oxygen 4 Air The controller causes the v...

Page 96: ...EEN will appear 5 For the OUTPUT TYPE select any type other than GAS MIX and for the OUTPUT ACTION select DIRECT 6 The Press OK to accept these settings and return to the LOOP CONFIGURATION SCREEN 7 I...

Page 97: ...ication the oxygen control loop must have a cascade input from the DO control loop If there is no oxygen control loop it must be added to the controller configuration Perform the following to setup th...

Page 98: ...e OUTPUT TYPE select GAS MIX and for the OUTPUT ACTION select 2 Ch Comp 17 Enter the PWM PERIOD in seconds the default value is 10 seconds by pressing on the text box and entering in the time using th...

Page 99: ...l appear 20 Select SSR 4 as the OUTPUT TYPE and choose the corresponding CONNECTOR ID the group of four SSRs that the gas solenoid valves will be connected to 21 Press OK to accept these settings and...

Page 100: ...et up responds to culture DO demand with changes in agitation for DO loop outputs between 0 and 50 then with gas flow for DO loop outputs between 50 and 65 and finally with oxygen enrichment for DO ou...

Page 101: ...fset 60 Controller Loop Name Gas Mix Sterilization Output Device Output Device B Output Device A Conn Type N A Conn Type SSR 4 Recorder Conn None Type N A Scaling N A Filter Gain N A Filter Band N A M...

Page 102: ...e default value is 10 seconds by pressing on the text box and entering in the time using the keyboard The PWM PERIOD is the time required to cycle once through all of the gas solenoid valves 7 Press O...

Page 103: ...CONTROLLER SETTINGS SCREEN will appear 5 For the OUTPUT TYPE select GAS MIX and for the OUTPUT ACTION select CENTER OFF 6 Enter the PWM PERIOD in seconds the default value is 10 seconds by pressing o...

Page 104: ...of the pH control loop is input to the DO loop The specific setpoint and output values in the cascade do not matter The Gas Mix algorithm alone determines the gas mix ratios 2 From the GAUGE SCREEN p...

Page 105: ...OOP CONFIGURATION SCREEN A message will appear press YES to accept changes to the DO loop NO to decline 12 Exit the MAIN CONFIGURATION SCREEN by pressing the CLOSE BUTTON The control mode of the DO lo...

Page 106: ...gas mix will be off press the area inside the Off Time text box Once the Cycle time and Off Time have been entered press the SET CYCLE BUTTON to start the gas mix cycle NOTE The gas mix cycle time is...

Page 107: ...is labeled from one to three The fourth pump is a user supplied auxiliary pump that is connected to the AC PUMP OUTPUT RECEPTACLE on the rear panel of the console The receptacle is controlled by the...

Page 108: ...25 1 70 20 1 4 35 2 4 L S 17 2 80 15 1 0 20 1 4 L S 18 3 80 15 1 0 15 1 4 As tested with Noprene Pharmed and Tygon Tubing Values will be lower for silicone and C Flex Tubing 14 2 Tubing Selection Outs...

Page 109: ...P0740 2405 P0740 2505 P0740 2540 P0740 2646 Silicone Peroxide 96400 13 96400 14 96400 16 96400 25 96400 17 96400 18 Silicone Platinum 96410 13 96410 14 96410 16 96410 25 96410 17 96410 18 Tygon Lab R...

Page 110: ...o and through the PUMP CHANNEL Flip the black PUMP LEVER on the PUMP HEAD to the right side and verify that the lever locks into place On the right outlet side of the PUMP HEAD press the black TUBING...

Page 111: ...tuator for a known period of time and measuring the accumulated total in volume mass etc To calibrate a total control loop In the GAUGE SCREEN set the loop setpoint from the display gauge to zero From...

Page 112: ...he CLOSE BUTTON If the pump or actuator flow or transfer rate is not known perform the following In the function window select the RUN FUNCTION The SET TOTAL BUTTON changes to a RUN button Enter the a...

Page 113: ...ges to an ABORT BUTTON To stop the calibration press the ABORT BUTTON see sample screen below After the RUN FUNCTION has counted down to zero the ABORT button changes to an ENTER BUTTON Using the onsc...

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Page 115: ...rough a 6 mm OD tube which enters through a fitting and adapter in a 19 mm ID port in the headplate Contact with foam activates a peristaltic pump which is connected aseptically to an appropriate port...

Page 116: ...Recorder Conn S1 J1 Type Conductance Scaling Cond Probe Filter Gain 1 Filter Band 0 Meas Limits N A Enabled No Conn N A Type N A 15 2 Setup of Foam Probe Attach the FOAM PROBE LEAD to FOAM PROBE and p...

Page 117: ...ing agents are at the discretion of the user This agent should be miscible with water and thermally stable at sterilization temperatures 121 C 130 C in order to sterilize it 15 3 High Foam Safety Syst...

Page 118: ...ation Output Device Output Device B Output Device A Recorder Conn S2 J2 Type Conductance Scaling Cond Probe Filter Gain 1 Filter Band 0 Meas Limits N A Enabled No Conn N A Type N A In order for the hi...

Page 119: ...also be configured to shut down the any number of loops To do so press the boxes near the name of each loop to be shut down A check will appear in the box to indicate that the loop was selected For d...

Page 120: ...e Input Input Device Mode Manual Output Action Reverse Type PWM 0 100 PWM Period 10 Gains P 0 I 0 D 0 Norm Const 100 Limits High 100 Low 0 Mode Local Conn N A Type N A From Foam Gain 0 01 Offset 0 Con...

Page 121: ...The pump rate is determined by the PWM period The foam loop is factory set at Pump 3 The cascade control scheme is as follows 15 5 Conductance Probe Calibration To calibrate control loops with the in...

Page 122: ...es Foam High Foam Level 80 0 80 0 60 0 NOTE A sensitivity of 100 will read full scale when there is no contact with the media and a sensitivity of 0 will not register a reading when the probe is immer...

Page 123: ...ddition of acid is introduced automatically into the vessel when pH is too low an addition of base is introduced automatically into the vessel In the PWM mode of control a timed addition can be used t...

Page 124: ...Type SSR Conn S5 J0 9 10 Type SSR Recorder Conn S5 RE1 Type Frequency Scaling Linear Filter Gain 1 Filter Band 0 Meas Limits N A Enabled No Conn N A Type N A 16 1 Calibration of pH Probe Inspect the...

Page 125: ...bes These probes do not require pressurizable housings 16 1 3 Calibration A two point calibration of the pH probe is performed with buffer solutions of known pH Optimum results will be achieved if the...

Page 126: ...to a second buffer solution with a nominal pH of 4 00 or 10 00 NOTE A pH buffer should be selected that will linearize the equipment in the range of the specific process For example if a process is ru...

Page 127: ...ting to the measured value Press CLOSE to exit this window 16 1 4 Recalibration After Sterilization To recalibrate a pH probe after sterilization Aseptically sample the culture medium Refer to the Sam...

Page 128: ...00 the installed pumps are numbered 1 through 3 A fourth auxiliary pump may also be utilized This is accomplished by connecting an auxiliary pump with the electrical receptacle provided on the rear pa...

Page 129: ...appear Select the control loop that you want to cascade from in this case pH The CASCADE SCREEN will appear The control loop selected i e pH will appear in the upper left as CASCADE FROM pH The loop...

Page 130: ...maximum setpoint for this loop Regardless of output of the cascade from loop the setpoint of this cascade to loop will not go above the value you enter here In the first data entry box of the last OUT...

Page 131: ...ypical control scheme for DO is as follows Figure 32 DO Control Loop Configuration Enabled No Conn N A Type N A Setpoint Cascade Input Input Device Mode Off Output Action Direct Type PWM 0 100 PWM Per...

Page 132: ...strategy Refer to the agitation control loop configuration scheme Operation maintenance and troubleshooting of DO probe and controller are described in corresponding manuals which accompany this manua...

Page 133: ...pear Select the DO control loop from the list by pressing on it Unplug the DO probe from the console NOTE Do not leave the DO disconnected from the fermentor for more than one minute Prolonged disconn...

Page 134: ...g of DO control loop display gauge Once the reading has stabilized press the CAL BUTTON The CALIBRATION SELECTION WINDOW will appear Select the DO control loop from the list by pressing on it The LOOP...

Page 135: ...ivity or Level probe is located in the headplate and is adjustable in height 18 2 Control Level is controlled by providing a signal to an assignable peristaltic pump located on the front panel of the...

Page 136: ...Type N A From N A Gain N A Offset N A Controller Loop Name Level Sterilization Output Device Output Device B Output Device A Conn N A Type N A Conn N A Type N A Recorder Conn S2 J1 Type Conductance S...

Page 137: ...set such that pump will stop when liquid level reaches the level probe Typical settings for a nutrient control loop are as follows Figure 34 Nutrient Control Loop Configuration Enabled No Conn N A Typ...

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Page 139: ...rations PID values and alarm settings are saved Current values trend data and setpoints of the control loops in the process are not saved When a configuration is loaded from disk all current controlle...

Page 140: ...l 3 Lift and slide the panel from the console The floppy drive should be visible It is mounted so that the face of the drive is facing down 4 Reconnect the power cord and turn the unit on 5 Insert a d...

Page 141: ...WORD is set to blanks the prompt will not appear The SAVE CONFIGURATION WINDOW will appear 4 Select the desired DRIVE and DIRECTORY Enter the appropriate file name in the text area using the onscreen...

Page 142: ...rompt will not appear When a configuration is loaded from disk it will replace the current displayed configuration NOTE If your BioFlo 4500 is equipped with an internal computer the drive designations...

Page 143: ...New Brunswick Scientific Co Inc User s Guide 143 7 Press OK to load the file 8 To return to the GAUGE SCREEN press CLOSE in the MAIN CONFIGURATION SCREEN...

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Page 145: ...e of cascade errors in DO are corrected by changes in agitation RPM This controller allows cascading from any loop to as many as five other loops Dissolved oxygen is the most commonly cascaded from lo...

Page 146: ...beled OUTPUT 3 In the first data entry box of the CASCADE column select the first control loop that will be cascaded to by pressing on the arrow in the first data entry box A loop list appears 4 Press...

Page 147: ...rom loop output that will produce the maximum setpoint entered in the previous column Higher outputs will not change the setpoint 9 This completes the setup for the first cascaded to loop If up to fou...

Page 148: ...irflow vary with DO output This output range is a region of overlap For DO output values greater than 80 agitation remains constant at maximum setpoint only airflow varies with DO output The following...

Page 149: ...n the graph The graph and data are only available when the fermentor is on Data cannot be stored saved NOTE Data archiving can be accomplished through the use of the BioCommand Supervisory Software pa...

Page 150: ...play on the graph by pressing on it 4 To set the low and high display limits of the graph press each text box and enter the values by pressing on the onscreen keypad The Clr BUTTON can be used to clea...

Page 151: ...ss the color you want to remove and select NONE as the control loop in the TREND GRAPH SET UP WINDOW 9 The time span options for trend graphs are 10 minutes 30 minutes 1 hour 2 hours and 4 hours Press...

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Page 153: ...ontrol loops In the GAUGE SCREEN the operator can only view eight 8 loop DISPLAY GAUGES at a given time After eight 8 loops the controller software places the remaining DISPLAY GAUGES on a second GAUG...

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Page 155: ...the GAUGE SCREEN press the ALARM BUTTON The ALARMS SCREEN will appear 2 If you wish to exit this screen press CANCEL If you want to continue select a loop from the process loop list by pressing on it...

Page 156: ...f the condition is below the normal limit 24 1 1 Alarm Mode Before setting alarm limits choose the desired ALARM MODE There are two possible selections ABSOLUTE The alarm will trigger when the Current...

Page 157: ...is selection triggers an alarm that is both visual and audible Any alarm will flash on the screen as described above and make a beeping noise NOTE External alarm is not active unless AUDIBLE is active...

Page 158: ...ed Then press OK to accept the selection The software will return to the ALARM STATUS SCREEN 24 3 Responding to Alarms When an alarm is triggered a thick red flashing line appears around the affected...

Page 159: ...ngs 24 3 1 Acknowledging the Alarm To acknowledge an alarm 1 From the GAUGE SCREEN press the ALARM BUTTON The ALARMS SCREEN will appear 2 Press the loop that is in an alarm condition The ALARM STATUS...

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Page 161: ...TROLLER INTERFACE SCREEN The BioCommand CONTROL CONFIGURATION SCREEN will appear 2 Touch the name of the loop where you wish to set the deadband 3 Touch CONFIGURE The LOOP CONFIGURATION SCREEN will ap...

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Page 163: ...o eight controllers from a single computer It can be used with the BioFlo 4500 For the controller to work with BioCommand the BioFlo 4500 must Be connected to the BioCommand Software via the 25 pin AF...

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Page 165: ...a run NOTE When preparing the fermentor bioreactor for a run always make sure that all hardware is set up to control the process prior to entering any setpoints or activating the system at the contro...

Page 166: ...on the console 9 Ensure that the fermentor bioreactor is ready to run by confirming that all the services have been properly connected and regulated 10 At the touchscreen ML 6100 Controller only make...

Page 167: ...equired components If media is added in this manner make sure that the headplate is reinstalled securely in place prior to turning on the system 27 3 Sterilization of Vessel Using Heat Labile Media Ce...

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Page 169: ...lements of the system 1 Before proceeding complete the Water Priming Procedure see Section 6 2 2 Insert the calibrated pH probe and the DO Foam and Level probes if used into the vessel Connect the pro...

Page 170: ...0 Turn on the fermentor and set the agitation rate at the touchscreen During sterilization Agitation control loop should be set to a rate of 150 200 RPM Turn on the Agitation control loop by putting t...

Page 171: ...below 28 1 1 Resetting Sterilization Parameters Enter the parameters by pressing on any of the text boxes and entering the values on the keyboard Press OK to accept the parameters The parameters are a...

Page 172: ...on cycle The operator may make changes to the valve sequencing by following these instructions To sequence a set of valves for automatic sterilization press the VALVE SEQ BUTTON in the AUTOMATIC STERI...

Page 173: ...not directly enter the vessel HEAT B Heating at temperatures above the HEAT B temperature setting in the AUTOMATIC STERILIZE PARAMETERS WINDOW at which steam directly enters the vessel STER Heating o...

Page 174: ...4 The factory settings for the sterilization valve sequence with media in the vessel are the following The factory settings for the sterilization valve sequence with the vessel empty are the following...

Page 175: ...oop has returned to its normal operating temperature setpoint To shut down or disable loops during sterilization 1 Press the SHUTDOWN BUTTON The STERILIZATION SHUTDOWN SELECTIONS WINDOW will appear 2...

Page 176: ...hase of the sterilization process will be displayed in the control mode of the selected control loop s display gauge 28 5 Aborting Sterilization The sterilization process may be stopped or aborted at...

Page 177: ...tly modified Because the sterilization process has been enabled the STERILIZE BUTTON has been replaced by the ABORT BUTTON 4 The word COOL will be displayed in the control mode of the control loop dis...

Page 178: ...erilized empty the instructions for sterilization with liquid in the vessel should be followed with the exception that the drain valve should be open instead of closed during sterilization The sterili...

Page 179: ...h though a hollow tube When the valve is in the forward position the tube is extended into the vessel to allow sterile liquid to be introduced into the vessel The prerequisites for sterile inoculum an...

Page 180: ...and aseptically attach an inoculation container using silicone or Tygon type tubing 4 To open the inoculation valve press the black polymer handles in toward the vessel and turn clockwise This brings...

Page 181: ...type ports 2 Remove steam port cap from inoculation addition valve and attach the quick connect to the port 3 Ensure that the stainless steel cap is in place 4 Open the STEAM INLET VALVE on the 19 mm...

Page 182: ...4500 M1254 0050 User s Guide 182 12 Close the valve on the quick connect 13 Detach the sterile quick connect from the inoculation addition valve 14 Replace the stainless steel cap 15 Re sterilize the...

Page 183: ...te trap The valve is designed to eliminate blind pockets and crevices When the control ring is turned clockwise the tube is extended into the vessel so that sterile liquid may be extracted To take a s...

Page 184: ...e etc sampling of liquid is usually accomplished by gravity and aseptically connect the sample line onto the quick connect fitting 4 To open the channel into the vessel turn the clear polymer CONTROL...

Page 185: ...line onto the quick connect fitting 5 Open the valve on the sterile quick connect 6 To open the channel into the vessel turn the clear polymer CONTROL RING clockwise This brings the valve s entrance...

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Page 187: ...m membrane should be used for each new process To assemble the septum port kit 1 Place the SEPTUM MEMBRANE into the headplate port 2 Check all O rings of the SEPTUM COVER and PLUG clean and replace if...

Page 188: ...kit allows sterile access to the culture vessel This kit requires a 19 mm headplate port equipped with a septum port kit The syringe port assembly is available with 3 mm bore PN M1214 5011 or 6 mm bor...

Page 189: ...puncture the septum 5 Prepare the addition bottle or container Place both the bottle and the syringe assembly in an autoclave and sterilize 31 2 1 Luer Lok Syringe Adapter A Luer Lok Adapter is avail...

Page 190: ...to the vessel The syringe assembly may be left on the vessel by clamping the tubing from the addition bottle or container 6 To remove the assembly unscrew the SYRINGE GUIDE from the SEPTUM COVER and r...

Page 191: ...se Barb Ports There are a variety of hose barb port options that can be used on the BioFlo 4500 headplate Single double and triple ports are available These ports are steam sterilized with the vessel...

Page 192: ...e following table NBS Part Number Hose Barb Port Assembly M1254 5041 Addition Port Assembly 1 16 1 5mm M1254 5042 Addition Port Assembly 1 8 3 17mm M1254 5043 Addition Port Assembly 1 4 6 35mm M1254 5...

Page 193: ...loop to OFF 2 Set the DO control loop to OFF 3 Set the Foam control loop to OFF 4 Set the Pressure control loop to OFF 5 Set the Airflow control loop to OFF 6 Stop Agitation 7 Stop steam supply to ve...

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Page 195: ...late 3 Keep Agitation at 200 300 rpm without aeration for about one hour at a temperature setpoint of 30 350 C 4 Flush all Sampling Addition and Harvest Ports with steam 5 Drain the water while the Ai...

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Page 197: ...do not use steel wool to clean the vessel To maintain better life from O rings and gaskets be sure all surfaces are clean and that gaskets and O rings are wiped clean before reassembling filter covers...

Page 198: ...eck valve may need to be cleaned more frequently 7 Check all hand valves on both the vessel and the piping skid for tightness of the valve packing just beneath the handle which should be tightened to...

Page 199: ...the O ring on the cartridge for tears resilience and other conditions that may interfere with sealing Apply a small amount of silicone grease to this O ring before reassembling Should this O ring be...

Page 200: ...uration will be erased 2 Remove the two Phillips head panel screws on the back panel setting them aside for reuse 3 Unplug the exhaust fan and carefully set the panel down Figure 44 Back Panel Removal...

Page 201: ...G A PROCESS CONFIGURATION 34 7 Motor Removal To replace the motor referring to Figure 45 1 Unplug the motor cable and the speed sensor cable 2 Unscrew the four black T handled bolts that secure the mo...

Page 202: ...Installation 1 Align the coupling on the driveshaft with the coupling on the motor and ease the motor into place 2 Reinsert and screw in the four black T handled bolts to secure the motor in place 3...

Page 203: ...t Local Controller is not responding No power to fermentor console External Computer Cable not connected properly Internal controller error Verify power cord connections Verify power switch operation...

Page 204: ...hat a single Node Number Unit ID or Multidrop Address value of 0 through 19 has been assigned to the Controller Assign a new Unit ID to equipment and verify that a single Node Number Unit ID or Multid...

Page 205: ...L M1254 9906 Bearing Housing Assembly 20 L Single Seal M1254 3015 Bearing Housing Assembly 20 L Double Seal M1254 2240 Bearing Housing Assembly 30 L Single Seal M1254 3017 Bearing Housing Assembly 30...

Page 206: ...uxiliary pump Watson Maslow 505 230 V P0620 0921 Auxiliary pump Masterflex Early Load II 115 V P0620 2410A Auxiliary pump Masterflex Early Load III 230 V P0620 2411A External cables for pump control v...

Page 207: ...e M1214 5013 Battery Holder Assembly M1254 5023 1 5V Battery P0480 9030 External Computer Cable 20 ft M1218 8039 Replacement Vessel Lamp Bulb with pushbutton P0300 0209 Vessel Light with pushbutton P0...

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Page 209: ...xygen FNPT Female National Pipe Thread FS Full Scale HP Horsepower ID Inner Diameter MAWP Maximum Allowable Working Pressure NPT National Pipe Thread OTR Oxygen Transfer Rate PID Proportional Integral...

Page 210: ...BioFlo 4500 M1254 0050 User s Guide 210 SSR Solid State Relay UPS Uninterruptible Power Source VCO Vacuum Connector O ring VVM Vessel Volume per Minute W x D x H Width x Depth x Height...

Page 211: ...New Brunswick Scientific Co Inc User s Guide 211 3 38 8 D DR RA AW WI IN NG GS S 38 1 Control Schematics Figure 46 Basic Control Schematics Detail A SEE DETAIL B...

Page 212: ...BioFlo 4500 M1254 0050 User s Guide 212 Figure 47 Basic Control Schematics Detail B SEE DETAIL A...

Page 213: ...New Brunswick Scientific Co Inc User s Guide 213 Figure 48 Power Schematics SEE DETAIL A Figure 50 SEE DETAIL B Figure 51...

Page 214: ...BioFlo 4500 M1254 0050 User s Guide 214 Figure 49 Power Schematics Detail A...

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