Sartorius DCU 3 Operator'S Handbook Manual Download

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Operators Handbook

BAEDCU3 - Rev. 4.6 - 0504

D C U 3 - S y s t e m

Digital Measurement and Control System for Fermentors

Summary of Contents for DCU 3

Page 1: ...Operators Handbook BAEDCU3 Rev 4 6 0504 D C U 3 S y s t e m Digital Measurement and Control System for Fermentors...

Page 2: ......

Page 3: ...or can be combined into a project specific document Design installation start up and use of the fermentor system are shown in the extra operating manual of this unit More detailed technical informati...

Page 4: ...Operators Handbook DCU3 System Introduction BAEDCU3 Rev 4 6 0504...

Page 5: ...ed by the Main Menu 4 1 5 Main Function Calibration 5 1 General Note 5 1 5 2 pH Calibration 5 2 5 3 pO2 Calibration 5 4 5 4 Redox Calibration 5 5 5 5 Calibration of Turbidimetry Measurement 5 6 5 6 To...

Page 6: ...29 6 19 Pressure Controller 6 30 6 20 Gravimetric Dosing Controller 6 31 6 21 Setpoint Profiles 6 33 6 22 Timers 6 35 6 23 Alarm Limits of Process Values 6 37 6 24 Alarms of Digital Inputs 6 39 7 Main...

Page 7: ...tion Menu 10 1 10 2 Report Printer 10 1 10 3 Recorder Configuration 10 3 11 Main Function Password 11 1 12 Main Function INFO 12 1 13 Alarms 13 1 Alarm Messages 13 1 13 2 Alarm Menu 13 2 14 Supplement...

Page 8: ...Operators Handbook DCU3 System Contents BAEDCU3 Rev 4 6 0504...

Page 9: ...stem will always depend on the specifications of the customer as agreed prior to ordering of the fermentor system Therefore even specific customized configurations are possible Standard functions are...

Page 10: ...Operators Handbook DCU3 System 1 Design and Function BAEDCU3 Rev 4 6 0504 1 2...

Page 11: ...ing switched on again the DCU3 will start at return to a defined state of operation All controllers are off actuators are in rest position All timers are off stopped No recipe loaded no program steril...

Page 12: ...tes the shut down function Then all outputs of the DCU are reactivated 2 4 Interlocking Functions Interlocking functions trigger the outputs for functions which are important for operational safety i...

Page 13: ...able to provide an optimum angle of vision DCU Tower BIOSTAT B DCU 1 Unscrew the locating screw of the support at the rear of the terminal a little 2 Push the terminal backward at its upper edge or pu...

Page 14: ...mate dd mm yyyy hh mm ss 2 line Alarm line display of alarms showing the latest alarm 3 line name of active function in the working area Working area display of schematic setup of fermentor system and...

Page 15: ...ailable in the working area of the oper ating displays Selection key Function Exit Closes the actual display PARAM Request for display of related parameters PV Alarm Request for display of related pro...

Page 16: ...larm parameters Maintenance Manual access to inputs and outputs measurement ranges of process values parameters of remote systems such as host computers balance systems and to the maintenance service...

Page 17: ...ls At multible vessel fermentor systems the main menus of the subunits can be accessed as follows Via the touch key integrated in the overview display showing the vessel no of the subunit only for DCU...

Page 18: ...tors Handbook DCU3 System 3 Function Selection and Inputs BAEDCU3 Rev 4 6 0504 3 6 Switching over the main menu dis plays for 2 4 culture vessels via direct function key CHANGE UNIT CHANGE UNIT CHANGE...

Page 19: ...rating terminal Applicable for DCU3 system which are prepared for controlling several fermentors culture vessels 3 2 Inputs 3 2 1 Numerical and Non numerical Inputs Example for entering numerical inpu...

Page 20: ...accessed Special Notes What do touch keys indicate whose label appears in black white dithered light letters If a controller s mode is set to auto for instance the data entry for the controller output...

Page 21: ...s parameters Above this it is the starting point for easy access to the submenus and subfunctions for inputs and selections 4 2 Process Information Provided by the Main Menu The main menu displays the...

Page 22: ...n this laser printed manual shown light grey see example for the entry of foam measurement 4 2 2 Invalid Process Values If a process value is invalid the display changes to see example flow 4 2 3 Dire...

Page 23: ...ion agent pumps for dosing counters Balance the functions required for pre setting of balance systems such as zero taring and tare correction You will enter all inputs at the touch terminal Context ba...

Page 24: ...mpact of heat during the sterilization can cause a zero drift of the electrode To compensate for such effects the DCU3 system allows to recalibrate the pH electrode during the process You can measure...

Page 25: ...h the culture medium for instance 1 Measure the actual pH value in a sample taken from the running fermentation using con ventional pH measuring techniques 2 Start the calibration by pressing the Star...

Page 26: ...O2 the actually measured electrode current the actual temperature and the zero and slope current together with the calibration conditions This in addition allows a simple function control of the pO2 e...

Page 27: ...eys values and functions available in this display REFBU mV Enter reference voltage of redox buffer 5 4 2 Functional Check The electrode function is checked before it is mounted into the culture vesse...

Page 28: ...and the zero deviation against 0 AU This allows for an easy func tional check of the sensor The lamp contained in the turbidimetry sensor can be switched on and off via the Sensor Calibration menu se...

Page 29: ...sensor proceed as follows 1 Start the calibration via Start Calibration 2 Follow the instructions of the calibration menu 5 5 3 Special Notes 1 If the lamp1 is switched on it will be kept in on state...

Page 30: ...calibration process from the measured running time and the entered delivery volume The standard configurations of the DCU system include calibration routines and dosing counters for acid base antifoam...

Page 31: ...he pump 2 Start the calibration of the pump via Start Calibration 3 Follow the instructions shown at in the DCU3 display The DCU system automatically calculates the flowrate considering the internally...

Page 32: ...rrection is possible after changing the equipment of the culture vessel during a running process For this the net weight is stored and the tare weight will be adapted to the changing gross weight 5 7...

Page 33: ...to the DCU3 without hardware extensions One extension allows for up to 12 measurements The system calculates the volume delivered per time the massflow considering the actual weight measured with the...

Page 34: ...is calculated from the shortest interval This is also true when a new setpoint is defined for the dosing controller The same is true for presetting a new setpoint of the dosing controller 3 For manua...

Page 35: ...mputer The extent of implemented controllers depend on the fermentor system and or the individual customized configuration The controllers shown below can be implemented at present Temperature control...

Page 36: ...ending on process value SETP PV input of setpoint entry physical unit depending on process value MODE input of controller mode off master controller and servo controller switched off auto master contr...

Page 37: ...egC for TEMP rpm for STIRR pH for pH value sat for O2 saturation etc SETP PV Input of setpoint in the physical unit of the process value such as degC for TEMP rpm for STIRR pH for pH value etc MODE In...

Page 38: ...and PID controllers the controller outputs can be limited MIN and MAX Thus unintended high actuator changes can be avoided and for cascade controllers the setpoint for the servo controller can be limi...

Page 39: ...e of process value MAX Input of minimum output limit representing the setpoint minimum for the servo controller 0 100 measuring range of process value DEADB PV Input of deadband physical unit dependin...

Page 40: ...roller alle PID Parameter defined 6 4 5 PID Controller Optimization An optimum adaptation of a PID controller to its control loop requires detailed knowledge in control theory You may refer to any sta...

Page 41: ...he set point which minimizes overshooting When the temperature controller is switched off an additional digital output switches off the circulation pump and the heating contactor in the fermentor The...

Page 42: ...JTEMP 6 5 4 Special Notes When the master controller is in auto or profile mode the servo controller is automatically switched over into cascade mode When the master controller is in off mode the ser...

Page 43: ...peed controller can be switched as a servo controller in the pO2 cascade control loop 6 6 1 Operating Display For a description of the tags the physical units or entries the displayed value or functio...

Page 44: ...neral 6 7 2 Special Notes In manual mode when entering the MIN MAX output limits and entering data into OUT allways observe the permissible measuring range of the corresponding airflow rate BIOSTAT ED...

Page 45: ...ption of the tags the physical units or entries the displayed value or function and of the required inputs see the table in section 6 3 Controller Operation in General 6 8 2 Operating Information For...

Page 46: ...ic MIN MAX range for the setpoint signal transmitted to each servo controller When the pO2 control is switched on at first the output of the pO2 controller operates the setpoint input of the priority...

Page 47: ...in section 6 3 Controller Operation in General Additional functions of this Operating Display are the following Tag Entry Displayed value or function required input CASCADE Input of servo controller f...

Page 48: ...maximum setpoint for servo controller 0 100 measuring range process value XP Input of proportional range for servo controller PARAM in rela tion to measuring range TI sec Input of reset time ifor ser...

Page 49: ...erned is out of its range for the delay time set in HTIME After this delay period the switch over condition will be checked again and the controllers then be switched over only if the condition is sti...

Page 50: ...iption of the tags the physical units or entries the displayed value or function and of the required inputs see the table in section 6 3 Controller Operation in General Additional functions of this Op...

Page 51: ...Input of minimum output limit considering the minimum setpoint for servo controller 0 100 measuring range process value Maximum Input of maximum output limit i e the maximum setpoint for servo contro...

Page 52: ...ble in section 6 3 Controller Operation in General 6 12 2 Special Notes Depending on the process requirements the control can be based on the following gases alternate supply of N2 and air at low O2 c...

Page 53: ...ntroller and can be used in two modes Control of the total gas flow TOTAL The setpoint for the total flow is manually adjusted The pO2 gasflow controller provides a setpoint for the portion of Gas 1 R...

Page 54: ...GAS2 slpm Flowrate Gas2 e g air RATIO Input of ratio of Gas 1 to total flowrate external setpoint in mode cascade master controller Contr has access to RATIO TOTAL slpm Input of total flowrate of Gas1...

Page 55: ...e defined only once Afterwards only setpoint and controller mode of the master controller pO2GF need be set 6 13 5 Special Notes In the operating modes auto and profile of the master controller the se...

Page 56: ...tem reduces the flow rate of the massflow controller for air supply and triggers a second massflow controller to add oxygen to the air inlet The increase of oxygen input is propertional to the decreas...

Page 57: ...e or function and of the required inputs see the table in section 6 3 Controller Operation in General Additional functions of this Operating Display are the following Tag Entry Displayed value or func...

Page 58: ...agent to the culture The pump or dosing valve is switched on and off periodically The dosing times and cycle time for intermittent operation can be entered into the control display 6 15 1 Operating D...

Page 59: ...foam sensor should be set as low as possible 1 Reduce the sensitivity down from position high until only foam is just detected 2 Adjust the cycle time CYCLE and the dosing time according to your proc...

Page 60: ...equipped with an output for measured signal Above this the extended functions of the DCU3 system allow the specification of time profiles for set points as well as recipe dependent setpoints for the...

Page 61: ...the DCU3 system offers several control strategies that can be selected the operator according to the requirements of the process 6 17 1 1 Single Sensor Control with Harvest Pump Control This control m...

Page 62: ...e on active inputs only in mode manual PULSE m s Input of reset time for the pump in minutes seconds SENSI low high Setting of the sensitivity for the amplifier DI ALARM Enabling the display of digita...

Page 63: ...via pulse width modulated outputs 6 18 1 Operating Display For a description of the tags the physical units or entries the displayed value or function and of the required inputs see the table in sect...

Page 64: ...a an I P converter The pressure controller can operate as a servo controller in the pO2 cascade control circuit 6 19 1 Operating Display For a description of the tags the physical units or entries the...

Page 65: ...ered volume considering the weight change It can ensure a constant flow by continuous control of the external pump This control function directly acts upon the input weight signal delivered from the b...

Page 66: ...ing range of the controller output OUT must be within 15 90 For this the delivery of the pump can be preselected by use of a tubing of the appropriate size or a pump head with an appropriate membrane...

Page 67: ...Temperature Control Profile Tag Entry Displayed value or function required input MODE Input of status of the profile stop profile inactive after loading of recipe start setpoint profile automatically...

Page 68: ...etpoint profile is started the controller mode in the main menu CONTROL LOOPS is automatically switched over to profile If the time for the first breakpoint is not set to 00 00 h m the system uses the...

Page 69: ...be processed The timers can be started and stopped at any time For running timers the display shows the passed time ELAPT 6 22 1 Operator Display Tag Entry Displayed value or function required input...

Page 70: ...le for timer operation in profile mode 6 22 3 Special Notes If the timer runs in the MODE profile the program must start at the time 00 00 h m In the profile mode the last condition programmed for the...

Page 71: ...m can be confirmed via the ACK key and the next alarm is displayed An alarm buffer stores up to 20 alarm messages not being confirmed The latest alarm is displayed on the alarm line on the screen Curr...

Page 72: ...e ACK nowledge key to confirm This also deletes this alarm message 2 The display of the process value changes its colour to red The DCU System displays an alarm as long as the process value exceeds th...

Page 73: ...d in customized DCU configurations 6 24 1 Operating Display Tag Entry Displayed value or function required input ALARM MODE Input for selection of the alarm monitoring disab Alarm monitoring of digita...

Page 74: ...Operators Handbook DCU3 System 6 Main function Control Loops BAEDCU3 Rev 4 6 0504 6 40...

Page 75: ...i zation medium sterilization sterilization of transfer installations intermediate sterilization for air inlet filter and for exhaust filter etc The structure of sterilization programs such as step ch...

Page 76: ...the sterilization such as opening or closing manual valves a corresponding message appears on the display The automatic sterilization will only continue after the required step is done and you have co...

Page 77: ...ossible since another sequence or recipe is active inactive sterilization program inactive ACK Request for Acknowledgement display see alarm messages in the supplement PHASE Display of the sterilizati...

Page 78: ...program the top line displays the process status STATE active If the process time has not yet been activated it will automatically start when the sterilization program is started Running sterilization...

Page 79: ...ss time clock at zero or at a predefined time If no process time is active the clock starts automatically with the sterilization program or when a recipe is loaded for the first time 7 3 1 Operating D...

Page 80: ...Operators Handbook DCU3 System 7 Main function Batch Control BAEDCU3 Rev 4 6 0504 7 6...

Page 81: ...cesses You can create up to four different recipes from the following sets of parameters Setpoints and operating modes of controllers Setpoint profiles for controllers Timer parameters Alarm limits an...

Page 82: ...Operators Handbook DCU3 System 8 Main Function Recipes BAEDCU3 Rev 4 6 0504 8 2 After selecting a recipe you can select the recipe parameter sets via the following menu...

Page 83: ...pe you can switch over the mode for this controller to no change during input of the recipe parameters 8 3 1 Operating Display Example for Temperature Controller Tag Entry Displayed value or function...

Page 84: ...Temperature Controller Tag Entry Displayed value or function required input MODE Additional input of state of profile for recipe Setpoint profile will not be effected by the recipe 8 4 2 Special Notes...

Page 85: ...ut MODE Additional state of timer for recipe no change recipe does not effect the timer 8 5 2 Special Notes Detailed information about the timers is included in section 6 22 Timers Timers that should...

Page 86: ...e recipes should not influence the alarm monitoring for certain process variables the alarm state must be set to no change while entering the corresponding recipe 8 6 1 Operating Display Tag Entry Dis...

Page 87: ...f a digital input should not be influenced by a recipe the alarm state of this digital input must be set to no change when entering the recipe 8 7 1 Operating Display Tag Entry Displayed value or func...

Page 88: ...Operators Handbook DCU3 System 8 Main Function Recipes BAEDCU3 Rev 4 6 0504 8 8...

Page 89: ...a a selection menu 9 1 1 Selection Menu Maintenance Note Most of the functions for system maintenance and trouble shooting are password pro tected to prevent unauthorized access Access to maintenance...

Page 90: ...into their corresponding menu to simulate a process Settings entered in manual mode have top priority they will override all other settings and functions of inputs and outputs of the DCU system 9 3 Ma...

Page 91: ...cal channel assignment DIMnn Digital Input Measurements internal digital inputs of measurement amplifiers DIPnn Digital Input Process digital input from process 9 3 3 Special Notes The following signa...

Page 92: ...outputs you can enter the pulse control factor in terms of Internally several functions are able to trigger one digital output The active function will be displayed in the Mode section The following...

Page 93: ...ed on nn pulse control factorfor pwm digital outputs in the range of 0 100 9 4 2 Abbreviations TAGs for Digital Outputs For a complete listing of the abbreviations TAGs for digital outputs refer to th...

Page 94: ...tag of analog input manual setting of operating mode and input signal MODE auto normal operation external input triggers function of the DCU3 system manual manual operation input of input signal in ha...

Page 95: ...evel can configured within 0 10 V 0 100 0 20 mA 0 100 4 20 mA 0 100 In the manual operating mode only the relative signal level 0 100 for the analog in puts is displayed or must be entered The assignm...

Page 96: ...l operation locking Lowest priority controllers etc 9 6 1 Operating Display Column Entry Meaning I O Addr Tag Name AO 01 STIRR AO 02 AIRFL etc Display of tag of analog output manual input of operating...

Page 97: ...nt Unassigned spare outputs have their physical channel assignment as TAG Example AOPnn Analog Output Process analog output for process 9 6 3 Special Notes The physical signal level of the analog outp...

Page 98: ...ery correspond with the fermentor system to which the DCU3 system is assigned to Only authorized service personnel is allowed to change the settings of this menu 9 7 1 Operating Display Tag Entry Disp...

Page 99: ...ce for connection of peripheral units such as pro tocol printers or a laboratory balance system The parameters for connection of a protocol printer to the DCU3 system can be entered via the func tion...

Page 100: ...In addition a host computer can be connected via a se rial interface RS 232 available via the peripheral interface PERI You must enable the data transmission between DCU and host system via the REMOT...

Page 101: ...letely which may occur after a software reset of the system Plug assignment plans of the host computer interface are described in details in the Techni cal Manual DCU system A detailed description of...

Page 102: ...umber of stop bit PARITY even no Input of type of parity check ALARM Input of state of alarm function enable alarms are transmitted disable alarms will not be transmitted 9 10 2 Default Settings for P...

Page 103: ...layed value or function required input PROTOCOL Selection of balance protocol Sartorius Protocol SARTORIUS all actual new balance systems Mettler Protocol METTLER MT SICS LEVEL 0 and previously suppli...

Page 104: ...r on disable beeper off FAILTIME h m Input of power failure time FAILTIME in hours minutes for system behavior after restart The system will behave as follows power failure FAILTIME system continuous...

Page 105: ...ring of malfunctions Prior to a system reset you should record your most important parameters and settings This will allow you to easily reconfigure your system according to your requirements This is...

Page 106: ...Operators Handbook DCU3 System 9 Main function Maintenance BAEDCU3 Rev 4 6 0504 9 18...

Page 107: ...terface The printer software offers the following possible protocols Trend line printout for 10 selectable process values with an adjustable printing interval and selectable statistical analysis Alarm...

Page 108: ...onal records calib calibration data alarm limits of process value alarms MODE operation mode for record start selected records are printed stop interruption of record printout TYPE input of parameter...

Page 109: ...ent range for the process values 10 3 1 Operating Display Tag Entry Displayed value or function required input Channel 1 6 Display of recorder channel Process Value Tag PV Input of process value Tag o...

Page 110: ...Operators Handbook DCU3 System 10 Main Function Documentation BAEDCU3 Rev 4 6 0504 10 4...

Page 111: ...the setting of controller parame ters PID etc the setting of interface parameters and the manual operation If a function is selected which is password protected then a numercal display for entering t...

Page 112: ...word Field Entry Function required input PASSWORD 0 9 Enter the standard password Special Notes After a software reset the default setting for the standard password 9 is available again The multi leve...

Page 113: ...tion Info i e such as System parameters Hotline Display Info Field Entry Function required input Software Vers Display of actual version of the implemented software Configuration Display of the instal...

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Page 115: ...rm Messages Alarm Messages will be displayed in the second line of the touch display and if connected on a re mote terminal The messages include a short reference for the kind of alarm and in the righ...

Page 116: ...rating Display Tag Entry Displayed value or function required input ACK Confirmation of single alarms ACK ALL MESSAGES Confirmation of all existing alarms ALARM MESSAGE OVERVIEW Display of all unackno...

Page 117: ...perating Manual of fermentor Motor failure overheat protection of motor is acti vated let motor cool down before switch ing on fermentor again TEMP Sens failure Pt 100 in culture vessel is defective o...

Page 118: ...lure occurred HH hours and MM minutes ago max interval of mains failure passed see Operating Behavior Confirm alarm with ACK nowl edge Printer not ready Printer protocol enabled but data transmission...

Page 119: ...1st FIB XXX error code Check cable connection check peripheral device may be malfunctioning 2 FIB not inst 102 2nd FIB missing or installed incorrectly Check board address reset to delivery state sen...

Page 120: ...6 175 The analog inputs AIP01 AIP17 of the 4th FIB are malfunctioning Send a claim note for the FIB 4 FIB AI17 32 175 The analog inputs AIP17 AIP32 of the 4th FIB of the analog input extension are are...

Page 121: ...with ut most care If problems arise with the use of the DCU system malfunctions technical problems the user or the customer service should return a detailed description of the problem The operator or...

Page 122: ...dosing counter acid pump delivered volume BASE dosing counter alkali pump delivered volume AFOAM dosing counter antifoam agent pump delivered volume SUBS process value nutrient solution pump AIRFL pr...

Page 123: ...U switched on SUPON status signal from basic unit mains switch basic unit switched on 14 4 3 Digital Outputs Tag Displayed value or function required input HEAT status signal from culture vessel jacke...

Page 124: ...ocuments Interface Parameters Baud rate see configuration documents Parity see configuration documents number of stop bits see configuration documents type of handshake software handshake Miscellaneou...

Page 125: ...esentative of Sartorius BBI Systems GmbH or Sartorius AG for further support or write directly to Sartorius BBI Systems GmbH Dept FA Product engineering automation projects Schwarzenberger Weg 73 79 D...

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