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Table 10.3. Pinout for PT 100 RTD for Lauda TCUs.

Item

Description

Integrator connector (female
receptacle)

ERA.1S.304.CLL (mixed female and male)

Integrator connector

FFA.1S.304.CLAC42Z

Connector manufacturer

LEMO

AWG of flying leads

3-wire RTD

Connector Wiring

- PT100 signal

- PT100 signal (jumper)

+ PT100 signal

Thermo Scientific

Single-Use Systems Integrator’s Guide

Figure 10.2.

Lauda TCU - front panel

access and communication ports.

Chapter 10

TCU communication connection

Summary of Contents for HyPerforma 2.1 S.U.B.

Page 1: ...Single Use Systems Hardware Integrator s Guide DOC0039 Revision A July 2017 ...

Page 2: ......

Page 3: ...ic e box information 17 Chapter 3 Motor connection 19 3 1 Units without Thermo Scientific e boxes 19 3 2 Units with the Thermo Scientific e boxes 27 3 3 Motor general information 28 Chapter 4 Resistive heater connection 30 4 1 Units without the Thermo Scientific e box 31 4 2 Units with the Thermo Scientific e box 32 4 3 Resistive heater general information 34 Chapter 5 Load cell connection 36 5 1 ...

Page 4: ...nnection 49 8 1 Units without the Thermo Scientific e box 50 8 2 Units with the Thermo Scientific e box 52 Chapter 9 Pinch clamp connection 53 9 1 Tubing style pinch clamp 53 9 2 Film manifold style pinch clamp 54 Chapter 10 TCU communication connection 56 10 1 Neslab TCUs 57 10 2 Lauda TCUs 59 10 3 TCU connections general information 61 Chapter 11 Dip switch functionality 62 11 1 Top DIN rail in ...

Page 5: ...cations Your satisfaction with the scope and content of this publication is important to us Please send any corrections or suggestions you have for this guide or for any other Thermo Scientific technical publication to TechnicalDocumentation ThermoFisher com Related publications Please contact Thermo Fisher for information about the related publications listed below Publication Description Thermo ...

Page 6: ...rage or handling in an improper inadequate or unapproved manner such as but not limited to failure to follow the documentation or instructions in the deliverables or related to the equipment operation outside of stated environmental or other operational specifications or operation with unapproved software materials or other products k manufacture in accordance with requirements you gave us l insta...

Page 7: ...ly product label or limited use label license This equipment is intended for research use or further manufacturing in bioprocessing applications and not for diagnostic use or direct administration into humans or animals we do not submit the equipment for regulatory review by any governmental body or other organization and we do not validate the equipment for clinical or diagnostic use for safety a...

Page 8: ...O Normally Open PV Present Value PID Proportional Integral Derivative temperature controller PLC Programmable Logic Controller RPM Rotations per Minute RTD Resistive Temperature Detector SP Set Point SSR Solid State Relay S U B Single Use Bioreactor S U F Single Use Fermentor S U M Single Use Mixer S U S Single Use System TCU Thermal Control Unit used on water jacketed vessels VAC Volts Alternatin...

Page 9: ...gitation when the volume in a S U B drops below defined limits and speed based governors prevent damage to the drive shaft in the bioreactor We recommend the use of speed governors and safety interlocks to prevent the hazardous conditions listed below Operating the motor at any speed while loading the drive shaft Operating the agitator when volumes are less than 50 of a sys tem s working volume fo...

Page 10: ... the system outside of recommended volumes which could damage the hardware and the BPC and result in the loss of a cell culture batch Agitation rate calculations Using power input to volume P V ratios Using power input to volume ratios for agitation speed The power input to volume ratio P V allows for scale up or scale down of bioreactor platforms by equating mixing power between differently sized...

Page 11: ...m 3 are provided in Table 1 1 below Table 1 1 Equation coefficient values A for different S U B s n A x V 1 3 for values of n in RPM 50 L S U B 100 L S U B 250 L S U B 500 L S U B 1 000 L S U B 2 000 L S U B P V 20 W m 3 49 650 31 491 18 634 12 764 8 471 5 950 40 W m 3 62 554 39 676 23 477 16 081 10 673 7 031 Coefficient value is used to determine operating speeds for drive shafts implemented for ...

Page 12: ...04 90 75 67 65 158 127 102 88 73 65 60 154 123 99 85 71 63 55 150 120 96 83 69 61 50 145 116 93 80 68 60 5 1 Systems Only 45 140 112 90 78 65 57 40 135 108 86 75 62 55 35 129 103 83 71 60 53 30 122 98 79 68 57 50 25 115 92 74 64 53 47 20 107 85 69 59 50 44 Using these RPM values requires replacement of the drive shaft after 180 days of use RPM values assume the system is operating at no less than ...

Page 13: ...imum agitation rates in RPM for S U B s at a P V of 40 W m3 Using the 2 000 L S U B above 20Wm 3 requires con sultation with Thermo Fisher Engineering 50 L S U B 100 L S U B 250 L S U B 500 L S U B 1 000 L S U B 2 000 L S U B Fill 2 1 and 5 1 Systems 100 230 184 148 127 109 95 227 181 145 125 105 90 222 178 143 123 103 85 218 174 140 121 101 80 214 171 137 118 99 75 209 167 134 116 97 70 205 164 1...

Page 14: ...1 000L S U B systems 2 000L S U B systems have a longer drive shaft which experiences more stress related fatigue Minimum acceleration and declaration rates required fomr 2 000L S U B systems are from 0 RPM to 75 RPM in 60 seconds and from 75 RPM to 0 RPM in 60 seconds Acceleration and deceleration rates for agitation rates above 76 RPM must be calculated at 1 25 RPM per second 1 3 Drive shaft lon...

Page 15: ...hould be reduced as the pressure inside the BPC approaches 0 5 psi 0 03 bar Any time the pressure exceeds 0 5 psi 0 03 bar in the BPC the gas flow should be stopped 1 5 Motor cap safety sensor An optional safety switch may be installed on the motor cap of all single use systems This device uses a reed switch that is normally closed when the cap is closed When the cap is open a safety interlock sho...

Page 16: ...single use systems hardware A typical single use system S U S is shown in Figure 2 1 The major sub components are noted although some sub components vary based on the type of unit Single Use Bioreactor S U B Single Use Mixer S U M or Single Use Fermentor S U F 2 Figure 2 1 View of a typical S U S in this case a 300L Single Use Fermentor ...

Page 17: ...U S It may not be provided with fully integrated units but it can be used by third party integrators who do not want to spec out components to control motor RPM pressure monitoring weight monitoring temperature monitoring and or temperature control of resistive blanket units Integrators who want to build and specify their own electrical components may order units without the Thermo Scientific e bo...

Page 18: ...Figure 2 3 E box bottom view Thermo Scientific Single Use Systems Integrator s Guide 18 Figure 2 4 E box side view Chapter 2 Electrical Box Overview ...

Page 19: ...provides information for third party integrators on how to connect standard AC and DC powered motors supplied on the S U S 3 1 Units without Thermo Scientific e boxes 3 1 1 AC motor The AC motor comes with a 4 pin male receptacle on the J box as shown in Figure 3 1 3 Figure 3 1 Typical AC motor 4 pin male receptacle ...

Page 20: ...art C01620D00311012 Controller connector female receptacle Part C01620G00310012 Connector manufacturer Amphenol Recommended AWG 16 4 shielded Wiring Pin 1 U phase Pin 2 V phase Pin 3 W phase GRD GRD Figure 3 2 AC motor connector Table 3 1 shows the connection pinout for the AC motor The table includes information for the mating female connector if the integrator wants to build a motor power cable ...

Page 21: ...or the AC motor power cable Figure 3 4 shows a close up of the connector on the cable Figure 3 3 Thermo Scientific motor power cable Table 3 2 AC motor connection table Item Description Hood Socket Thermo Scientific Electrical Box connector male receptacle SH606 075 MS206 Controller connector female inline CH806 075 FS106 Controller connector female receptacle 714 406 FS106 Connector manufacturer ...

Page 22: ...s a typical DC motor The motor comes standard with hardwired cords The typical length of the power cable the hall effects sensor and the encoder cable is about 10 feet The typical length of the fan power cable is about 6 feet Figure 3 4 6 pin connector on Thermo Scientific AC motor power cable Thermo Scientific Single Use Systems Integrator s Guide 22 Encoder Figure 3 5 DC motor ...

Page 23: ...012 Controller connector female inline Part C01620D00311012 Controller connector female receptacle Part C01620G00310012 Connector manufacturer Amphenol Recommended AWG 16 4 shielded Wiring Pin 1 U phase Pin 2 V phase Pin 3 W phase GRND GRND Figure 3 6 Connector for DC motor power cable Chapter 3 Motor Connection Single Use Systems Integrator s Guide 23 ...

Page 24: ...troller connector female receptacle Part FKFD4 5 0 5 Connector manufacturer Turck Recommended AWG 22 5 shielded Wiring Pin 1 Pole sensor power supply 15V Pin 2 U phase pole signal output open collector Pin 3 V phase pole signal output open collector Pin 4 W phase pole signal output open collector Pin 5 Ground Figure 3 7 Connector for DC motor hall effects cable Chapter 3 Motor Connection Single Us...

Page 25: ...1 0 Controller connector female inline Part BWS 8151 0 Controller connector female receptacle Part FKFDW 4 5 0 5 Connector manufacturer Turck Recommended AWG 22 5 shielded Wiring Pin 1 Ground Pin 2 Index Pin 3 A channel Pin 4 5 VDC Pin 5 B channel Figure 3 8 Connector for DC motor encoder cable Chapter 3 Motor Connection Single Use Systems Integrator s Guide 25 5 ...

Page 26: ...350 crimp pin Controller connector female inline PX0411 03S 5560 SA3348 crimp socket Controller connector female receptacle PX0413 03S SA3348 crimp socket Connector manufacturer Bulgin Bulgin Recommended AWG 20 2 20 2 Wiring Pin L 24 VDC Pin N 0 VDC Pin E N A Figure 3 9 Connector for DC motor fan power cable Chapter 3 Motor Connection Single Use Systems Integrator s Guide 26 ...

Page 27: ...he speed reference input to the VFD This switch needs to be adjusted to the appropriate position depending on what input is being used Refer to Section 12 for proper settings Refer to Table 3 8 for the scaling factors associated with each vessel size Table 3 7 Pinout for 16 pin communication cable Item Description Shell Insert Thermo Scientific connector male receptacle SH616 710216 Integrator con...

Page 28: ...e stainless steel Motors are aluminum bodied and protected with an industrial gray paint The DC motors are a 3 phase brushless type built to run on 48 VDC input voltage They feature standard hall effects sensors a 2 channel encoder The encoder counts at 1 000 CPR DC motors are fully sealed units rated to IP65 protection rating Thermo Scientific attaches an external fan to help cool the motor near ...

Page 29: ... 500 L HP 5 1 356 60 1 000 L HP 5 1 356 60 2 000 L 1 HP 5 1 356 60 S U F 30 L HP 5 1 596 101 300 L 2 HP 5 1 375 63 2 Table 3 9 Vessel size and gear ratio DC motor Vessel type Vessel size DC motor size Gear ratio Maximum RPM Motor max Hz S U B 50 L 200 W 10 1 214 51 4 100 L 200 W 10 1 214 51 4 250 L 200 W 10 1 178 42 7 500 L 400 W 20 1 152 73 1 000 L 400 W 20 1 118 56 6 2 000 L 400 W 20 1 75 36 S U...

Page 30: ...ird party integrators on how to connect to the resistive heaters It also discusses the functionality of the proportional integral derivative PID temperature control loop included in the Thermo Scientific e box Resistive heaters are only offered on the S U B product line This guide only covers integration of generation II style S U B s approximately 2013 or newer 4 ...

Page 31: ...re run without a thermal mass to transfer the heat Table 4 1 Pinout for resistive heater cable Item Description Hood Insert Contact Thermo Scientific connector male inline 19 20 003 1440 19 12 005 3001 09 33 000 6 102 pins Integrator connector female inline 19 20 003 1750 09 12 005 3101 09 33 000 6202 sockets Integrator connector female receptacle 09 20 003 0306 09 20 003 0306 09 33 000 6202 socke...

Page 32: ... is described below 4 2 1 Option 1 Internal temperature control by Thermo Scientific e box Ensure that the PID dip switch is in the Down position This enables local control of the resistive heaters and the internal bath temperature The operator will set the desired temperature on the Fuji temperature controller and the heaters will drive to that temperature setting Figure 4 1 Internal resistive he...

Page 33: ...nput Signal connection This signal closes a relay and sends power to the resistive heaters The integrator uses this input as well as feedback from the RTD to correctly control the process bath temperature This connection is on the side of the e box as shown in Figure 2 3 The external temperature control option enables pins 9 10 and 11 and disables pins 12 and 13 on the 16 pin communication cable T...

Page 34: ...PT 100 enabled or disabled according to DIP switch position Pin 11 RTD output signal PT 100 enabled or disabled according to DIP switch position Pin 12 Temp output signal 4 20 mA enabled or disabled according to DIP switch position Pin 13 Temp output signal 4 20 mA enabled or disabled according to DIP switch position 4 3 Resistive heaters general information Table 4 4 Power consumption of resistiv...

Page 35: ...re controller mA output Fuji Note Thermo Scientific will not take responsibility for the installation wiring documentation support and or parameter setup of the recommended components The part numbers listed in the previous table are only provided as a reference for integrators who may not be familiar with the components Thermo Scientific Single Use Systems Integrator s Guide 35 Chapter 4 Resistiv...

Page 36: ... but are not configured with Thermo Scientific e boxes will be supplied with an 8 pin connector This connector will communicate the raw load cell signal of mV V to the third party controller It is scaled at 2 mV V per the excitation voltage The signal references the full scale value of the combined total of the three load cells For example A 250 L S U B with 3 200 kg load cells will have total cap...

Page 37: ...ne Part B 8181 0 Integrator connector female receptacle Part FKFD 8 0 5 Connector manufacturer Turck Recommended AWG 22 5 shielded Wiring Pin 1 SIG Pin 2 SEN Pin 3 SIG Pin 4 EXE Pin 5 SHLD Pin 6 SHLD Pin 7 SEN Pin 8 EXE Figure 5 1 Pinout for load cell summing block cable Thermo Scientific Single Use Systems Integrator s Guide 37 Chapter 5 Load cell connection ...

Page 38: ...ut for 16 pin load cell communication cable Item Description Shell Insert Thermo Scientific connector male receptacle SH616 710216 Integrator connector Flying leads Flying leads Connector manufacturer Walther Walther AWG of flying leads 20 20 Connector Wiring Pin 1 Load cell communication Analog 4 20mA AB RIO Blue Profibus RTS DeviceNet V Pin 2 Load cell communication Analog 4 20 mA AB RIO shield ...

Page 39: ... use Mettler Toledo TM load cells belonging to the families listed below Each unit has exactly three load cells All wires are routed into the cart of the vessel and they are attached to the summing block The summing block is located at the back underside of the cart Flexmount Used on all legacy products until March 2014 This product has been discontinued by Mettler Toledo and has been replaced by ...

Page 40: ...vessel size It is a three wire resistance canceling RTD All RTDs are 100 ohm thin film Pt RTD Class A equipment with tolerances from 30 C to 350 C The RTD is rated from 0 C 200 C It is offered in either a single element or a dual element configuration with multiple types of connectors Table 18 lists several available RTDs 6 1 Units without Thermo Scientific e boxes The RTD on units supplied withou...

Page 41: ...l 6 2 Units with Thermo Scientific e boxes The RTD on units supplied with Thermo Scientific e boxes will plug into the side of the e box as shown in Figure 2 4 It communicates through the 16 pin communication cable On resistive e boxes verify that the dip switch that controls the PID temperature control loop is set in the Up position This setting will pass the raw PT 100 signal though to pins 9 10...

Page 42: ...cturer Walther Walther AWG of flying leads 20 20 Connector Wiring Pin 9 RTD output signal PT 100 enabled or disabled according to DIP switch position Pin 10 RTD output signal PT 100 enabled or disabled according to DIP switch position Pin 11 RTD output signal PT 100 enabled or disabled according to DIP switch position Thermo Scientific Single Use Systems Integrator s Guide 42 Chapter 6 RTD Connect...

Page 43: ...o Scientific 120 inch double RTD SV50177 248 2 Bulgin standard DB9 Male Thermo Scientific 120 inch double RTD SV50177 363 1 Bulgin standard N A Thermo Scientific 120 inch single RTD SV50177 233 1 Flying leads N A Thermo Scientific 120 inch single RTD SV50177 240 1 DB9 male N A Thermo Scientific 120 inch single RTD for Neslab TCUs SV50177A 08 1 Lemo connector N A Thermo Scientific 60 inch single RT...

Page 44: ...e will be needed to communicate with the pressure sensor The output of the sensor is 0 2584 mV psi V with an excitation voltage range of 2 5 to 10 VDC Lower excitation voltages yield a more stable pressure signal 7 1 Units without Thermo Scientific e boxes On units supplied without the Thermo Scientific e box the integrator will connect to the pressure sensor cable Thermo Scientific part number SV...

Page 45: ...Pin 4 Excitation 7 2 Units with Thermo Scientific e boxes Units that come with Thermo Scientific e boxes will always have pressure transducers The pressure sensor cord will plug into the pressure sensor input plug on the side of the e box The plug location is shown in Figure 2 4 The raw pressure signal is then routed internally to the pressure transducer and output as a 4 20 mA signal This signal ...

Page 46: ...t 0 5 psi It is recommended that this set point remain at the default value The pressure alarm is a dry contact and is available as a normally open NO or a normally closed NC contact Table 7 3 Pinout for pressure alarm receptacle Item Description Shell Pins Thermo Scientific connector male receptacle PX0412 03S SA3348 crimp pin Integrator connector female inline PX0411 03P 4550 SA3347 crimp socket...

Page 47: ...pin Integrator connector female inline PX0411 03S 5560 SA3349 crimp socket Integrator connector female receptacle PX0413 03S SA3349 crimp socket Connector manufacturer Bulgin Bulgin Recommended AWG 22 3 silver plated copper 22 3 silver plated copper Connector Wiring Pin E Common Pin N NC contact Pin L NO contact Figure 7 2 Pressure sensor receptacles Thermo Scientific Single Use Systems Integrator...

Page 48: ...output Omega Thermo Fisher will take no responsibility or consultation on the installation wiring documentation support and or parameter setup of the recommended components The part numbers listed above are only provided as a reference to integrators who may not be familiar with the components Thermo Scientific Single Use Systems Integrator s Guide 48 Chapter 7 Pressure Sensor Connection ...

Page 49: ...r with an inline temperature controller 46 series Figure 8 1 or without a controller type K Figure 8 2 Both options come in either 120 VAC or 240 VAC The 46 series heaters come with an IEC C14 male plug that will plug directly into the bottom of the Thermo Scientific e box Each Type K heater comes with an M12 style fitting that connects to and is managed by the integrator s control box 8 Figure 8 ...

Page 50: ...es the heater temperature to 55 C It is a factory sealed non adjustable module Table 8 1 Pinout for 46 series vent filter heater plug Item Description Thermo Scientific connector male inline IEC C14 Integrator connector female receptacle IEC C13 Connector manufacturer Mouser Recommended AWG 16 3 SO style cord Connector Wiring 120 VAC 240 VAC Pin E Ground Ground Pin N Neutral Line 2 Pin L Load Line...

Page 51: ...r heater plug Item Description Thermo Scientific connector male inline BS 8141 0 PG 9 Integrator connector female inline B 8141 0 PG 9 Integrator connector female receptacle FKFD 4 4 0 5 Connector manufacturer Turck Recommended AWG 20 4 Connector Wiring 120 VAC 240 VAC Pin 1 Line Line Pin 2 Neutral Line Pin 3 TC TC Pin 4 TC TC Thermo Scientific Single Use Systems Integrator s Guide 51 Chapter 8 Ve...

Page 52: ...eater Pinouts for this style of heater are shown in the previous section Type K heaters For units supplied with Thermo Scientific e boxes the vent filter heater must be plugged into the integrator s control box The temperature must also be controlled by the integrator It is recommended that 46 series heaters be used when the S U S has a Thermo Scientific supplied e box Pinouts for this style of he...

Page 53: ...mp tubing that is typical of the BPC It will clamp up to 1 inch diameter tubing The second type of pinch clamp connection is used to clamp the film manifold that is typical on the BPC used with S U F systems It will seal a 2 D film manifold that is 5 375 inches between the two mounting pins The Thermo Scientific e box does not support the pinch clamp so there is no difference of integration based ...

Page 54: ...ill release the clamp and will spring return it to the Open position The integrator will supply a constant 24 VDC to the BRN wire as shown in Table 9 1 To open the clamp from the programmable logic controller PLC a 24 VDC voltage is required on the BLK wire of the cable as shown in Table 9 1 This will engage a relay and the clamp will spring return to the open position This 24 VDC voltage should b...

Page 55: ...nnector female inline Choice of integrator Integrator connector female receptacle Choice of integrator Connector manufacturer N A Recommended AWG 22 5 Connector Wiring BRN 24 VDC constant WHT N A BLU 0 VDC BLK 24 VDC Relay to open clamp GR Y GRND Thermo Scientific Single Use Systems Integrator s Guide 55 Chapter 9 Pinch Clamp Connection ...

Page 56: ...CU type features RTD connection and communication ports These ports are different on each brand of TCU Two basic control schemes are discussed below Other control schemes may be used at the integrator s discretion Control Scheme 1 Process bath controlled by TCU PID values In this control scheme the RTD output signal is connected to the TCU The TCU will then control the process bath using its inter...

Page 57: ...ures RS485 signals and a DB15 connector for analog and relay communications The back panel has a connection point for a remote sensor input via a DB9 connector RS232 and RS485 signals are the industry standards The pinout is not presented in this publication Figure 10 1 Neslab TCUs back panel connections Thermo Scientific Single Use Systems Integrator s Guide 57 Chapter 10 TCU Communication Connec...

Page 58: ... 7 Reservoir temperature output 1 10 VDC 8 Low flow relay output dry contact form A to digital ground 9 Configurable relay output dry contact form A NO to pin 11 10 Configurable relay output dry contact form A NO to pin 11 11 Relay common 12 Remote start enable tie to pin 1 to allow remote on off control via pin 14 13 Remote set point tie to pin 1 to allow control via remote set point 14 Remote st...

Page 59: ...zes and the connection is the same for all units The connection point is on the front of the unit It is accessed by pulling out the bottom of the display panel Ports are located on the bottom face of this access panel Lauda TCUs feature RS232 and RS485 serial communication for communication to the third party controller Read and write commands are discussed in the Lauda operation manual RS232 RS48...

Page 60: ...tegrator connector FFA 1S 304 CLAC42Z Connector manufacturer LEMO AWG of flying leads 3 wire RTD Connector Wiring 1 PT100 signal 2 PT100 signal jumper 3 PT100 signal 4 PT100 signal Thermo Scientific Single Use Systems Integrator s Guide 60 Figure 10 2 Lauda TCU front panel access and communication ports Chapter 10 TCU communication connection ...

Page 61: ...rocess value output from Lauda 10 3 TCU connections general information Table 10 5 shows a list of RTDs offered by Thermo Scientific for use with the TCUs Table 10 5 Available RTDs for use with TCUs Thermo Scientific part number Number of outputs Output plug type Manu facturer Description TCU brand SV50177 240 1 DB9 female Thermo Scientific 120 inch single RTD Neslab SV50177A 08 1 Lemo 4 pin Therm...

Page 62: ...nside the Thermo Scientific e box These switches are grouped into two groups two switches on the top DIN rail and five switches on the bottom DIN rail Each switch has a small label behind it on the back panel that identifies the function of the switch 11 1 Top DIN rail in the left most position Reset bypass ON OFF On Up Enables agitation restart after e stop engagement without pressing the green b...

Page 63: ...Down Allows DeviceNet or profibus load cell communication on pin 16 of the 16 pin cable VFD speed input 3 position switch Up Allows 0 10 VDC external control of the VFD through the 16 pin cable Middle Allows local control of the VFD through the keypad Down Allows 4 20 mA external control of the VFD through the 16 pin cable Temperature PID On Up The temperature controller is off which allows extern...

Page 64: ...on analog 4 20 mA AB RIO Blue Profibus RTS or Device Net V 2 Load cell communication Analog 4 20 mA AB RIO Shield Profibus TDX RXD or Device Net Can L 3 Load cell communication AB RIO clear Profibus TXD RXD DeviceNet drain Modbus green 4 VFD speed control common 0 VDC 5 VFD speed control input 0 10 VDC positive 6 VFD speed control input 4 20 mA positive 7 VFD speed reference output 0 10 VDC positi...

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