TruTorr II Single-Use Sensor User’s
Guide
DOC0065 • Revision A
December 2019
Thermo Scientific
Contents
Warnings, safety, and warranty information 1
How to use this Guide 3
Chapter 1 TruTorr II single-use sensor overview 4
1.1 Trutorr II Sensor description 4
1.2 Main components 5
1.2.1 TruTorr II Sensor 5
1.2.2 Cable 6
1.2.3 Transmitter 7
Chapter 2 Unpacking and installing the TruTorr II sensor 8
2.1 Unpacking the TruTorr II sensor 8
2.2 Installing the TruTorr II sensor 8
2.3 Installing the transmitter 9
2.3.1 Mechanical installation 9
2.3.2 Electrical installation 10
Chapter 3 Operating information 12
3.1 Overview 12
3.2 TruBio Software pressure controller 12
3.3 Main faceplate 13
3.4 Detail display 14
3.5 Control configuration 17
Chapter 4 Calibration 20
Chapter 5 Troubleshooting 21
5.1 Overview 21
5.2 Troubleshooting fault outputs 21
Chapter 6 Maintenance 22
Thermo Scientific
Contents
Chapter 7 Specifications 23
7.1 Ordering specifications 23
7.2 Measurement specifications—primary 24
7.3 Transmitter specifications—primary 25
Chapter 8 Regulatory compliance 26
Warnings, safety, and warranty information
Thermo Scientific
Warnings, safety, and warranty
information
Congratulations! You have purchased a high-quality Thermo
Scientific™ product. We have included safety information in this Guide,
based on our knowledge and experience. It is important, however, for
you to work with your safety management personnel to ensure that
this product is integrated into your safety practices. Please take some
time to perform your own job safety analysis in order to identify and
control each potential hazard.
WARNING: Read and understand this User’s Guide before
using this product.
TruTorr II sensors must be properly used and maintained to ensure
they continue to operate within their normal specifications. The
instructions in this Guide must be adhered to and integrated into
your safety program when using and maintaining Thermo Scientific
products. Failure to follow the proper instructions may cause
any one of the following situations to occur: loss of life, personal
injury, property damage, damage to the instrument, and warranty
invalidation.
WARNING: Follow all warnings, cautions, and instructions
marked on and supplied with the product.
Inform all personnel in the proper operation and maintenance of the
product. Connect all products to the proper electrical and pressure
sources.
Warranty information
Any warranties, if applicable, covering this equipment exclude:
(a) normal wear and tear; (b) accident, disaster or event of force
majeure; (c) your misuse, fault or negligence; (d) use of the equipment
in a manner for which it was not designed; (e) causes external to
the equipment such as, but not limited to, external puncturing,
power failure or electrical power surges; (f) improper storage and
handling of the equipment; (g) use of the equipment in combination
with equipment or software that we did not supply; (h) equipment
sold to you as ‘used’ products; (i) contact with improperly used or
unapproved chemicals or samples; (j) installation, removal, use,
maintenance, storage, or handling in an improper, inadequate, or
TruTorr II Sensor User’s Guide | 1
Thermo Scientific
Warnings, safety, and warranty information
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) not operating the equipment
according to our operation and maintenance guide; (l) installation of
software or interfacing or use of the equipment in combination with
software or products we have not approved; (m) the performance,
efficacy or compatibility of specified components; and (n) the
performance of custom equipment or products or specified
components or achievement of any results from the equipment,
specified components or services within ranges desired by you
even if those ranges are communicated to us and are described in
specifications, a quote, or a statement of work.
ADDITIONALLY, ANY INSTALLATION, MAINTENANCE, REPAIR,
SERVICE, RELOCATION OR ALTERATION TO OR OF, OR
OTHER TAMPERING WITH, THE EQUIPMENT PERFORMED BY
ANY PERSON OR ENTITY OTHER THAN US WITHOUT OUR
PRIOR WRITTEN APPROVAL, OR ANY USE OF REPLACEMENT
PARTS WE HAVE NOT SUPPLIED, WILL IMMEDIATELY VOID
AND CANCEL ALL WARRANTIES WITH RESPECT TO THE
AFFECTED EQUIPMENT. IF THE EQUIPMENT IS TO BE USED
IN THE UNITED STATES, WE MAY VOID YOUR WARRANTY IF
YOU SHIP THE EQUIPMENT OUTSIDE OF THE UNITED STATES.
WE DO NOT WARRANTY OR GUARANTEE THAT THE USE OF
THE EQUIPMENT WILL MEET ANY PARTICULAR REGULATORY
REQUIREMENTS, AND WE DO NOT INTEND FOR THE
EQUIPMENT DOCUMENTATION TO BE USED IN SUPPORT OF
YOUR REGULATORY APPROVALS.
Use restrictions
You must use this equipment in accordance with our documentation
and if applicable, with our other associated instructions, including
without limitation, a “research use only” 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 and effectiveness, or for any other
specific use or application.
TruTorr II Sensor User’s Guide | 2
Thermo Scientific
How to use this guide
How to use this Guide
Scope of this publication
This User’s Guide contains information about the Thermo Scientific™
TruTorr II Single-Use Sensor. It is intended for use by people who may
or may not have experience with Thermo Scientific systems.
Document change information
Revision Date Section Change made Author
A12/2019 -- Initial release E. Hale,
T. Golightly
Questions about this publication
If you have any questions or concerns about the content of this
publication, please contact technicaldocumentation@thermofisher.
com and your Thermo Fisher Scientific sales team.
Abbreviations/acronyms
Refer to the list below for definitions of the abbreviations and
acronyms used in this publication.
ARW Anti-reset windup
BPC BioProcess Container
CO Controller output
EMC Electromagnetic compatibility
FCC Federal communications commission
PHV Process history view
PID Proportional integral derivative
PV Process variable
RoHS Restrictions of hazardous substances
RTD Resistance temperature detector
SP Setpoint
TC Time constraint
USP United States Pharmacopeia
VAB Vessel adapter box
TruTorr II Sensor User’s Guide | 3
Thermo Scientific
Chapter 1 | TruTorr II single-use sensor overview
TruTorr II single-use
sensor overview
1.1. TruTorr II sensor description
The TruTorr II is a single-use pressure sensor comprised of a
disposable sensor, a cable, and a transmitter. The transmitter
integrates signal processing, power conversion, and a 5-20 mA
output signal for range (4 mA when cable is disconnected for alarm).
The TruTorr II sensor format features a disposable 0.25 or 0.5 in.
diameter sheath that is inserted into a headspace port of a single-
use BioProcess Container (BPC) and that encapsulates the TruTorr
II sensor. Note that this is not a flow-through design, but rather the
sheath fits into the port, and the TruTorr II sensor sits at the end of the
sheath tube.
The TruTorr II sensor is aimed at preventing BPCs from bursting due
to overpressure in the BPC. Typical BPC (greater than 50 L in volume)
headspace pressures should be about 0 psi gauge (1 atm absolute
pressure), and operation above 3 psi gauge is considered unsafe.
Although a typical 50 L BPC will burst at 10 psi gauge, and a 1,000
L bioreactor BPC will burst at 3 to 4 psi gauge, manufacturers rate
the maximum headspace pressure at 0.5 psi gauge for all sizes as a
precaution.
Figures 1.1 and 1.2 illustrate the major components of the TruTorr II
sensor. Note: Figure 1.1 shows the transmitter unit for the original
TruTorr sensor. The new TruTorr II sensor unit is black instead of silver.
TruTorr II Sensor User’s Guide | 4
1
Thermo Scientific
Figure 1.1. The original TruTorr
pressure sensor transmitter.
TruTorr II Sensor User’s Guide | 5
The disposable TruTorr II sensor is connected to a feed-thru on the
controller chassis used in your system.
The disposable TruTorr II sensor is pre-inserted into a 0.5 in. port at
the top of a single-use bioreactor BPC, and measures the headspace
pressure of the BPC. The TruTorr II sensor is gamma-irradiated with
the BPC, and thereby provides a fully sterile connection. The TruTorr II
sensor and BPC are both disposed of after a run.
The TruTorr II transmitter provides a 5-20 mA analog output that
indicates the headspace pressure, and a 4 mA output for the alarm.
The TruTorr II transmitter does not have a display or user keypad
because it is intended to be directly used on a control panel, rather
than as a standalone transmitter. It is available as an option within the
TruViu hardware family.
Chapter 1 | TruTorr II single-use sensor overview
Cable
Disposable
sensor
Figure 1.2. Disposable TruTorr II sensor and
cable.
Thermo Scientific TruTorr II Sensor User’s Guide | 6
1.2.2. Cable
The TruTorr II sensor and transmitter are connected together using a
pre-assembled electrical cable (Figure 1.4), which can be 1.83, 3.05,
or 6.09 meters (6, 10, or 20 feet) long. The wire is shielded in order to
maintain a high signal-to-noise ratio at the transmitter electronics.
Figure 1.4. TruTorr II cables.
Chapter 1 | TruTorr II single-use sensor overview
Figure 1.3. TruTorr II sensors.
1.2. Main components
1.2.1. TruTorr II sensor
The TruTorr II sensor consists of a pressure sensor, a circuit board,
and a molded housing made from gamma radiation resistant, USP
Class VI materials. The TruTorr II sensor is designed to fit in a 0.25 in.
or 0.5 in. tube port. The TruTorr II sensor probe is connected to the
transmitter using an electrical cable either 1.83, 3.05, or 6.09 meters
(6, 10, or 20 feet) long.
Thermo Scientific
Chapter 1 | TruTorr II sensor overview
TruTorr II Sensor User’s Guide | 7
1.2.3. Transmitter
The TruTorr II electronics are housed inside the transmitter enclosure
(Figure 1.5), and are connected to the TruTorr II sensor probe using
an electrical cable as described above. The transmitter performs
the actual measurement of pressure and related signal processing.
The transmitter also provides a 4-20 mA output for pressure.
Note: Figure 1.5 shows the unit for the new TruTorr II sensor. The
original TruTorr II sensor transmitter is silver instead of black.
Figure 1.5. TruTorr II
sensor transmitter.
Thermo Scientific
Chapter 2 | Unpacking and installing the TruTorr II sensor
Unpacking and installing
the TruTorr II sensor
2.1 Unpacking the TruTorr II sensor
TruTorr II sensors are inspected and tested prior to shipment from the
factory. In the event that there is damage to the shipping container
(holes or crushing, etc.), we require that a representative of the
shipping carrier is present while you unpack the contents. Damage
caused by shipping is the responsibility of the shipping carrier and all
claims must be routed through their claims department.
Please note the following:
• Carefully unpack the contents from the box.
• Check contents of the box against the packing list to ensure all
parts have been received.
• Inspect each item to ensure there is no damage.
• It is recommended that you keep the shipping package until the
unit has been installed and verified as being fully operational.
2.2 Installing the TruTorr II sensor
The TruTorr II sensor system consists of a disposable sensor, cable,
and transmitter. The disposable TruTorr II sensor is pre-inserted into
the port of a single-use bioreactor (S.U.B.) BPC.
2
TruTorr II Sensor User’s Guide | 8
Thermo Scientific
Chapter 2 | Unpacking and installing the TruTorr II sensor
Each TruTorr II sensor is pre-installed in a 0.25 or 0.5 in. port located
at the top of the bioreactor BPC headspace. Therefore, only the cable
needs to be connected.
Line up the registration mark on the cable with the registration mark
on the TruTorr II sensor, and firmly insert the connector. Figure 2.1
shows a bioreactor vessel with a TruTorr II sensor and cable.
TruTorr II Sensor User’s Guide | 9
Figure 2.1. TruTorr II sensor inserted into a headspace port;
the black cable is connected to the sensor.
The TruTorr II sensor transmitter provides a 4-20 mA analog output:
5 mA = 0 psig, and 20 mA = 7 psig. Anything less than 4.5 mA
indicates a sensor failure or disconnected cable.
2.3 Installing the transmitter
2.3.1 Mechanical installation
The TruTorr II transmitter is intended to be pre-installed in a TruViu™
G3Pro™ (installed in supporting vessel adapter box [VAB]), G3Lite,™ or
G3Lab™ (installed in supporting VAB) system. These transmitters are
not sold as standalone products. The transmitter comes installed on
a DIN rail inside the TruViu cabinet, with 24 VDC power and analog
output already connected to the I/O of the hardware system (see red
and blue connections in Figure 2.2) via a Phoenix™ connector.
Note: Figure 2.2 shows the transmitter unit for the new TruTorr II
sensor. The original TruTorr II sensor transmitter is silver instead of
black.
Thermo Scientific
Chapter 2 | Unpacking and installing the TruTorr II sensor
TruTorr II Sensor User’s Guide | 10
Figure 2.2. 16-pin connector for power,
4-20 mA output, and sensor cable input.
Power (red)
4-20 mA output (blue)
Sensor cable input
(yellow)
For a TruViu system, the sensor side of the original cable is connected
to the TruTorr II sensor. The other end of the sensor cable sensor
is wired to a bulk head in the cabinet, and is pre-connected to a
Phoenix connector that plugs into the transmitter on the inside of the
cabinet (see yellow connections in Figure 2.2).
2.3.2 Electrical installation
The TruTorr II transmitter has two inputs, (the sensor cable and 24
VDC power), and one output (the 4-20 mA current indicating the
measured pressure). These three primary connections are made
through a 16-pin connector on the front of the transmitter. Figure 2.2
in the previous section shows the three primary connection areas on
the 16-pin connector.
Thermo Scientific
Chapter 2 | Unpacking and installing the TruTorr II sensor
TruTorr II Sensor User’s Guide | 11
Power supply wiring
For the input power, 24 VDC (± 10%) power with at least 30 mA
current is required. The “+” and “GND” supply wiring should be
observed.
Current loop wiring
The 4-20 mA output is device powered, i.e. the instrument supplies
the 4-20 mA current. Therefore, the TruTorr II transmitter output
should not be connected to a powered 4-20 mA loop that is intended
for two-wire transmitters or devices.
Probe cable wiring
The probe cable requires seven (7) pins on the 16-pin connector. The
primary connections are:
• Sensor power (“+5V” and “GND”); any yellow-colored GND
connection can be used
• Sensor pressure output (“SENS+” and “SENS-”)
• Cable shielding (“SHIELD”); either SHIELD connection can be
used
• I2C communication signals (“SCL” and “SDA”)
• THERM, reserved for future use
Note: Gamma irradiation can affect the turn-on voltage of
the ferroelectric RAM (FRAM) in the TruTorr II sensor. Before
every use, power the TruTorr II sensor on and leave for at least
30 minutes for acclimatization. The transmitter output will be
low (fault, less than 4 mA) until the FRAM turns on.
Thermo Scientific
Chapter 3 | Operating information
Operating information
3.1 O ve r v i ew
The TruTorr II sensor is primarily operated through the Thermo
Scientific™ TruBio™ Bioprocess Control Software. The software can
be used to display the current pressure reading, set alarm limits, and
activate alarms or interlocks for the process.
3.2 TruBio Software pressure controller
Information associated with the pressure controller is shown as a
control object on the top of the standard main display (Figure 3.1,
detail in [1]).
3
TruTorr II Sensor User’s Guide | 12
Figure 3.1. TruBio Software pressure control object box (1) and faceplate (2).
Thermo Scientific
Chapter 3 | Operating information
TruTorr II Sensor User’s Guide | 13
The control module object box includes the control module
description, process variable, setpoint, cascaded setpoint, an
alarm indication (a colored box appears if an alarm is activated or
unacknowledged), and a mode/interlock indication at the upper right
corner of the object box (display M for Manual mode, A for Auto
mode, C for Cascade mode, L for Local Override, and I for Interlock
active).
3.3 Main faceplate
The user can access the standard or main faceplate for the control
module by clicking on the object box. The main faceplate (Figure 3.2)
allows the user to:
• Observe controller output and process variable
• Change the control mode, controller output, and setpoint
• Open the detail display, control studio, process history view (PHV),
and acknowledge alarms
Figure 3.2. TruBio Software pressure main faceplate.
Close window
Process Variable (PV)
Alarm list
Alarm acknowledgement
Process history view
(PHV) historian
Control
studio
Detail
display
Pin window
Thermo Scientific
Chapter 3 | Operating information
TruTorr II Sensor User’s Guide | 14
3.4 Detail display
The pressure detail display is accessed from the main faceplate
by clicking on the “Detail display” button found on the bottom left
(Figure 3.2). The detail display has several tab options.
The pressure detail display allows the user to:
• Perform 1 pt. standardization and 2 pt. calibration of the probe
• Set the control loop tuning parameters
• Set setpoint, output, deviation, anti-reset windup (ARW), and
alarm limits
• Enable and/or suppress alarms
• Review sensor diagnostics
• Simulate values
• View and bypass the configured interlock conditions
The “Calibration” tab (Figure 3.3) allows the user to perform a one-
point standardization (by entering the value), or a full two-point
calibration of the TruTorr II sensor. This is a general TruBio Software
function for a general pressure sensor. Because each TruTorr II sensor
is pre-calibrated at the factory, this function is not necessary when
operating with a TruTorr II sensor. Zeroing the sensor may be a useful
function with the 1 pt. standardize.
The “Limits” tab sets the alarm levels (Figure 3.4). Standard alarms
(HI HI, HI, LO, LO LO) are set for the process variable to define an
acceptable working range. A deviation from SP alarm (HI or LO)
can also be set for a finer set of warnings. Limits can be set for
the controller output (OUT HI, OUT LO), for the setpoint to prevent
erroneous or non-physical SP values being entered, and for the
ARW for the PID control when the control output exceeds its LO and
HI boundaries. A probe deviation alarm can be set when using two
probes if the readings drift too far apart.
Figure 3.3. TruBio Software pressure detail display: “Calibration” tab.
Thermo Scientific
Chapter 3 | Operating information
TruTorr II Sensor User’s Guide | 15
The “Alarm Hysteresis” is used to prevent noise spikes in a PV to
cause the same alarm to trip numerous times. Namely, the alarm
value must return within the alarm limit by the amount of the alarm
hysteresis value (as a percentage of a scale) before the associated
active alarm clears. Specifically, Alarm Hysteresis displays the alarm
deadband value for the loop alarms in percentage of PV scale. An
alarm will not recur, but will remain an active alarm, until the PV has
backed away from the corresponding limit by at least the percentage
of PV scale specified by this value.
The “Conditional Alarms” button allows the user to set timing on
alarms. “Delay on” is the delay in seconds between an alarm going
off and the alarm condition being activated. “Delay off” is the delay
in seconds between an alarm being deactivated and the alarm
condition being removed. The “enable delay” is the delay in seconds
before activating an alarm, such as what would be used in a batch
process. The hysteresis values allow an error margin for the PV prior
to activating an alarm.
The “Tuning” tab (Figure 3.5) allows the user to view and change
the control loop’s tuning parameters, where Gain, Rate, and Reset
correspond to the PID parameters, TC is the loop time constant (to
filter noise on the signals), and SP Rate on/off is the rate at which a
loop will adjust its parameters when the SP is changed abruptly (in
engineering units). The “I deadband” disables the Reset (I) of the PID
loop when the PV is within the deadband (P and D control only). The
button in the lower center of the detail display page launches the
auto-tuner. Note: The DeltaV auto-tune requires a special license
from Emerson and can also do a one-point calibration through the
CAL routine.
Figure 3.4. TruBio Software pressure detail display: “Alarm
Limits” and “Conditional Alarms” tabs.
Alarm settings
Vx-PI-VSL
Thermo Scientific
Chapter 3 | Operating information
TruTorr II Sensor User’s Guide | 16
Figure 3.5. TruBio Software pressure detail
display: “Tuning Parameters” tab.
The “Alarms” tab (Figure 3.6) enables and suppresses the individual
alarms. There is a difference between enabling and suppressing
alarms, specifically:
• “Enable” will switch on the alarms and log them into the “Alarms
and Events” database. When an alarm occurs, the alarm banner
will flash.
• “Suppress” will not show the alarms.
• “Suppress and Enable” simultaneously will still log the alarms
into the “Alarms and Events” database, but they will no longer be
shown on the alarm banner. A button on the right of the alarm
banner will appear for viewing the suppressed alarms.
Figure 3.6. TruBio Software pressure detail
display: “Alarms” tab.
Vx-PI-VSL
Vx-PI-VSL
Thermo Scientific
Chapter 3 | Operating information
TruTorr II Sensor User’s Guide | 17
3.5 Control configuration
The user can set up a pressure control strategy by modifying the
Pressure Configuration Form from the Standard Configuration page
(Figure 3.8). The Pressure Control Configuration Form is shown in
Figure 3.9.
Figure 3.7. TruBio Sofware pressure detail
display: “Interlock” tab.
Vx-PI-VSL
The “Interlock” tab (Figure 3.7) allows the user to bypass an interlock
condition that was set for that specific control parameter or actuator
in the configuration page. For example, if an interlock is put on
pressure when a HI alarm on the TruTorr II sensor is triggered, i.e.,
the pressure exceeds a value close to the BPC rating, but is not
yet harmful to the BPC and the process is known to survive this
condition, the interlock could be bypassed in this page. Note:
Changing the interlocks may cause the system to operate outside of
the recommended specifications. In this case, the user should check
with their Thermo Fisher Scientific representative if they are uncertain
as to the ramifications of any change.
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