Sartorius DCU 3 Operator's Handbook Manual

Operators Handbook

BAEDCU3 - Rev. 4.6 - 0504

D C U 3 - S y s t e m

Digital Measurement and Control System for Fermentors

Operators Handbook DCU3 – System

Introduction

BAEDCU3 - Rev. 4.6 - 0504

Introduction

Sartorius BBI Systems´ digital measurement and control system for fermentors, the DCU3 – system, is

available as stand-alone unit for operation of Sartorius BBI Systems´ laboratory scale fermentors and

as a rack version for the measurement and control cabinets of pilot plant fermentors. All information

given in the handbook refer to the operation of these fermentors, unless otherwise specified. Above

this the DCU3-system can be applied as universal measurement and control system for fermentor

automation and for customized general measurement and control tasks.

This „Operator's Handbook“ describes all standard functions available with the software version 4.6 of

the DCU3 - system. In general the range of functions implemented for a specific fermentor is smaller

than the range that this manual describes. The DCU system can be adapted to the different fermentor

types by means of the software configuration and fermentor specific features.

 Besides the standard configurations the DCU3 - system can have customized configura-

tions, as required for special applications. The description of such configurations can be

added to this document 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 information on the hard- and software structure, the system instal-

lation, etc., is given in the extra „Technical Manual DCU3 - system“. If the DCU3 - system should be

used together with a host computer the corresponding protocol for communication is described in the

manual „DCU-Host Communication“. Both these manuals are available on request.

The digital control system DCU3 is one example of Sartorius BBI Systems´ product program of sophis-

ticated fermentation and peripheral laboratory equipment. For further information about this device and

our complete product program please contact the

 Sartorius BBI Systems GmbH

Schwarzenberger Weg 73-79

D - 34212 Melsungen

Tel.: +49 (0) 56 61 - 71 34 00, Fax: +49 (0) 56 61 - 71 37 02

e-mail: [email protected]

WebSite http://www.sartorius-bbi-systems.com

or your local representative of Sartorius BBI Systems GmbH or Sartorius AG.

Printed in Germany

of the equiment and changes of the related documentation are preserved. No part of the documentation shall be

changed or duplicated or reprocessed for other purposes by third parties without our written permission.

Printed in Germany

Operators Handbook DCU3 – System

Introduction

BAEDCU3 - Rev. 4.6 - 0504

Operators Handbook DCU3 – System

Contents

BAEDCU3 - Rev. 4.6 - 0504

Contents Page

Introduction

1 Design and Function 1 - 1

2 Operating Behaviour

2.1 Switching „off“ and „on“ 2 - 1

2.2 Mains Failure 2 - 1

2.3 Shut Down Function 2 - 2

2.4 Interlocking Functions 2 - 2

3 Function Selection and Inputs

3.1 Operating Terminal 3 - 1

3.2 Inputs 3 - 7

4 Start-Menü „Main“

4.1 General Notes 4 - 1

4.2 Process Information Provided 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 Totalizer for Pumps and Valves 5 - 8

5.7 Calibration of a Balance System 5 - 10

5.8 Flow Calibration 5 - 11

6 Main function „Control Loops“

6.1 Equipment and Functional Principles 6 - 1

6.2 Selection of Controller 6 - 2

6.3 Controller Operation in General 6 - 3

6.4 Parametrization of Controllers, in General 6 - 4

6.5 Temperature Controller 6 - 7

6.6 Stirrer Speed Controller 6 - 9

6.7 Airflow Controller 6 - 10

Operators Handbook DCU3 – System

Contents

BAEDCU3 - Rev. 4.6 - 0504

6.8 pH - Control Function Operating as PID - Controller 6 - 11

6.9 pO2-Control Methods 6 - 12

6.10 pO2 - Cascade Controller with 3 Servo Controllers 6 - 12

6.11 pO2 - Cascade Controller with 4 Servo Controllers 6 - 16

6.12 pO2-Gasmix Controller / O2 – Enrichment 6 - 18

6.13 pO2 - Gasflow Ratio Controller 6 - 19

6.14 Oxygen (O2) – Enrichment Using 2 Massflow Controllers 6 - 22

6.15 Foam Controller 6 - 24

6.16 Dosing Pump Controller 6 - 26

6.17 Level Controller 6 - 27

6.18 Weight Controller 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 function „Batch Control“

7.1 General 7 - 1

7.2 Sequences 7 - 1

7.3 Process Time 7 - 5

8 Main Function „Recipes“

8.1 Overview 8 - 1

8.2 Recipe Selection 8 - 1

8.3 Controller Parameters in Recipes 8 - 3

8.4 Setpoint Profiles 8 - 4

8.5 Timers in Recipes 8 - 5

8.6 Process Value Alarms in Recipes 8 - 6

8.7 Digital Input Alarms 8 - 7

9 Main function „Maintenance“

9.1 Overview 9 - 1

9.2 Manual Operation in General 9 - 2

9.3 Manual Operation for Digital Inputs 9 - 2

9.4 Manual Operation for Digital Outputs 9 - 4

9.5 Manual Operation of Analog Inputs 9 - 6

Operators Handbook DCU3 – System

Contents

BAEDCU3 - Rev. 4.6 - 0504

9.6 Manual Operation for Analog Outputs 9 - 8

9.7 Settings of Measurement Ranges 9 - 10

9.8 Connection of External Devices 9 - 11

9.9 Host Interface 9 - 12

9.10 Peripheral Interface 9 - 14

9.11 Balance Interface 9 - 15

9.12 System Settings 9 - 16

9.13 Service / Diagnostics 9 - 17

10 Main Function „Documentation“

10.1 Selection 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

14.1 Alarms, Meanings and Remedial Measures (Troubleshooting) 14 - 1

14.2 Trouble Shooting for the DCU-System 14 - 5

14.3 Interlocking Functions 14 - 5

14.4 Abbreviations 14 - 6

14.5 Fermentor - Specific Adjustments of Balance Systems 14 - 8

14.6 Arrangement and Assignment Plans 14 - 9

14.7 Declaration of Conformity with EC-Directives, Standards and

Technical Specifications 14 - 9

Operators Handbook DCU3 – System

Contents

BAEDCU3 - Rev. 4.6 - 0504

Operators Handbook DCU3 – System

1., Design and Function

BAEDCU3 - Rev. 4.6 - 0504 1 - 1

1 DESIGN AND FUNCTION

The Digital Measurement and Control System DCU3 has been especially developed for the automa-

tion of fermentor systems. The hardware is based on an industrial 32 bit VME bus micro processor

system. All measurement and control functions are implemented in the software. The software is

stored on a PC-card, which can easily be replaced for extensions of the system by new versions.

For the fermentors of the BIOSTAT® series the Sartorius BBI Systems GmbH offers a broad range of

standard configurations of the DCU3 – system, which consider the features of the individual type of

fermentor. However, the extent of functions implemented for a delivered system 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 data acquisition, sensor calibration, alarm monitoring and control of operation

conditions. Additional software modules provide control of process conditions by changing parameters

depending on running time and state of the process. This includes setpoint profiles for controllers,

timer functions for pulsed actuators, dosing counters, etc. Complete sets of process parameters may

be predefined as recipes to allow performing of reproducible process sequences.

The DCU3 can be integrated into hierarchical automation systems via its remote interfaces. A host

computer system can be connected, such as the proven MFCS-Systems, for instance, providing func-

tions like graphical visualization of processes, data acquisition and storage, process protocols, etc.

Operators Handbook DCU3 – System

1., Design and Function

BAEDCU3 - Rev. 4.6 - 0504 1 - 2

Operators Handbook DCU3 – System

2., Operating Behaviour

BAEDCU3 - Rev. 4.6 - 0504 2 - 1

2 OPERATING BEHAVIOUR

The DCU3 - system stores all parameters which are adjustable by the operator (setpoint, calibration

parameters, profiles, etc.) in a battery buffered memory. Hence these parameters are still available

when the DCU3 system is switched off and restarted again.

For enabling the outputs of the DCU3 - system and of several system functions, which directly act on

the fermentor system, 4 categories of switching-off or power failure, respectively, are differentiated:

1. Switching „off“ and „on“ using the mains switch at the front panel (see pos. 3 in fig. 1-1).

2. Shut down due to mains failure.

3. Emergency cut-off via the „SHUT-DOWN“-key at the operating terminal or using the mains

switch of the supply unit or cabinet of the fermentor (see BIOSTAT® MD, ED or BIOSTAT®

C-DCU3, UD, for instance).

4. Interlocking functions for system outputs.

2.1 Switching „off“ and „on“

The DCU3 - system is switched-on or off, respectively, via the mains switch on the front panel. After

being 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 (sterilization for example) active

2.2 Mains Failure

In the case of a (mains) power failure, after being restarted, the DCU3 - system continues its activities

as follows:

 Controllers run on with the setpoint, which has been adjusted at the time of the power failure

 Timers and setpoint profiles will be continued

 Sequences, such as sterilization programs, and recipes will be continued

The operator can set a maximum power failure time (FAILTIME) in the „maintenance“ menu. This is a

specific feature of the DCU3 - system. When the power failure lasts longer than the preset FAILTIME,

then the DCU3 - system behaves as if being switched-off with the mains switch, i.e. the system will be

shut down and set to a defined basic state.

After a power failure the system generates the message „Power Failure“, together with the time and

duration of the failure. If the maximum power failure time has expired (see „FAILTIME“), the system

displays the message „Pwf stop ferm“ with time and duration of the failure. See also the description of

the „Alarm messages“ in the supplement.

Operators Handbook DCU3 – System

2., Operating Behaviour

BAEDCU3 - Rev. 4.6 - 0504 2 - 2

2.3 Shut Down Function

The shut down function can be released by :

 Enabling the „SHUT DOWN“ key on the operating terminal and

 Enabling the mains switch of the fermentor (located on the supply unit or cabinet).

In the shut down state all outputs are switched over to their predefined safe state. Other active func-

tions of controllers, timers, profiles, recipes and sterilization are not effected.

 During the SHUT DOWN state you can change any of the active functions, as required.

 If the SHUT DOWN state is enabled, the DCU3 - system displays the alarm message „Shut

Down DCU“ or „SHUT DOWN FERMENTOR“

Pressing the „SHUT DOWN“ key again or restarting the fermentor supply unit with the emergency

switch terminates 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.e.:

 Fixed safety functions which cannot be changed by the user.

 User-definable safety functions.

An interlocking function switches certain outputs of the DCU3 over into their predefined safety state.

However, this will not effect the course of controllers, timers, profiles, recipes and of the sterilization.

For details about specific functions see section „Interlocking functions“ in the supplement.

If the cause for release of an interlocking function is no longer present, the safety state of the corre-

sponding output will be cancelled and the output returns into its operating state.

 The safety state of an output is the same as the state during SHUT DOWN.

 The state of the output displayed in the menu „MAINTENANCE, MANUAL OPERATION,

DIGITAL OUTPUTS“ and „ANALOG OUTPUTS“ is „lock“.

Operators Handbook DCU3 – System

3., Function Selection and Inputs

BAEDCU3 - Rev. 4.6 - 0504 3 - 1

3 FUNCTION SELECTION AND INPUTS

3.1 Operating Terminal

The DCU3 - system has an especially developed touch screen terminal for display of all process pa-

rameters and for operation of the entire unit. This „touch terminal“ has integrated „touch keys“ where

the operator can select the menus and the related subfunctions, enter data and select and switch-over

the modes for fermentor operation. In general the terminal is operated simply by pressing the screen

at the position of the displayed keys.

The touch terminal is adjustable 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 pull until

the display can be read best. Tighten the screw again.

DCU3-System in table top housing:

 BIOSTAT® MD-DCU3, Q-DCU-

3, C/CT-DCU3

1. Push the locking device on right hand of the terminal (see

push button 4 in fig. 1-1)

2. Pull the terminal at its lower edge or push backward, until

you achieve an angle where the display can be read best.

3. Release the locking device to fix the arrangement.

Rack version of DCU3 systems :

 BIOSTAT® D-DCU3, customized

pilot- and production fermentors

 The possible way of setting the angle depends on the

mounting of the terminal in the rack.

3.1.1 Structure of the Touch Screen Display

Operators Handbook DCU3 – System

3., Function Selection and Inputs

BAEDCU3 - Rev. 4.6 - 0504 3 - 2

Structure of the Touch Screen Display, on the page above shown for the „Main“ menu:

 1. line: Status line:

TAG Used for

hhhh:mm Display and Input of process time

Fermentation (etc.) Display of operating state. Possible displays are:

− Fermentation: System is in „Fermentation“ state

− Sequence: System runs a sequence

− Recipe 1..4: System runs a recipe (1..4)

18.01.00 14:03:11 Display of actual date and time in formate:

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 peripheral equipment;

– MAIN 2 : next „Main“-page

– the items displayed depend on the active function and can include symbols for devices,

process values, parameters, modes and settings;

– the displays of the items are designed as touch keys for direct access to submenus for

selecting functions and entering parameters.

 Lowest line: Main function keys (also designed as touch-keys) for selection of submenus

and subfunctions, where parameters should be entered and operating modes should be set.

Operators Handbook DCU3 – System

3., Function Selection and Inputs

BAEDCU3 - Rev. 4.6 - 0504 3 - 3

3.1.2 Functional Keys of the Working Area

For a selected function the lowest line of the working area can have additional touch keys, which are

especially assigned to this function and allow for direct access to the corresponding submenus.

 Example: Operating display of the pO2 - controller with touch keys:

 The following touch keys for function selection are available 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 process value alarms

PROFILE Request for display of related setpoint profiles

CALIB Request for display of related calibration function

Available keys not shown in this example are

CLOOP Selection of the related controller menu

CLOOPx Selection of additional controller displays

MAINx Request for display of related process overviews

TIMER Request for display of related timer functions

DI ALARM Request for display of related digital input alarms

Operators Handbook DCU3 – System

3., Function Selection and Inputs

BAEDCU3 - Rev. 4.6 - 0504 3 - 4

3.1.3 Selection of Menus and Entering of Parameters

The operation of the DCU3 - system is organized systematically. Related tasks of fermentor operation

are combined in functional groups - the „main functions“ listed below. A main function can be directly

activated at any time during the running process from any submenu by pressing the corresponding

main function touch key at the screen.

Main function Display, use

Main Graphic overview of the entire fermentor system showing the most important

process parameters and allowing for direct access to the related functions.

Calibration Calibration of sensors and pumps, taring of balance systems

Control Loops Operation of the controllers and related setpoint profiles and timers

Batch Control Operation of serial steps, batch processes, etc., such as sterilization runs

Recipes Operation of 4 recipes with preset controller parameters, setpoint profiles, tim-

ers and alarm 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) functions

Documentation Operation of recorders and printers for documentation of the process

Info Information about the installed software / general notes

There are two possible methods to select a menu, step forward to a subfunction and enter parame-

ters. As an example here are the possible methods for setpoint adjustment of the stirring speed:

 Stepping through the menu tree as known from the former DCU1- and DCU2- systems:

1. Select the main function „Control Loops“ by pressing the touch key

2. Select the „Stirrer“ controller from the overview of controllers

3. Adjust the setpoint

 Enabling the data entry function directly from the main menu. This is accomblished by object

(based) linking of the actual stirrer speed display in the main menu to the related controller

functions, i.e. „stirrer controller, setpoint profile and alarm limits“:

4. Press the „Stirrer“ - touch key in the working area of the main menu. The display directly

switches over to the menu of the stirrer controller.

5. Adjust the setpoint.

Operators Handbook DCU3 – System

3., Function Selection and Inputs

BAEDCU3 - Rev. 4.6 - 0504 3 - 5

3.1.4 „Touch keys“ in the Menu „Main“

After switching on of the system the graphical overview in the menu „Main“ provides a schematic dis-

play of the main functional elements of the individual fermentor system, together with the most import

process parameters and the „touch keys“ for selection of the related functions:

 Only for the single unit at fermentor systems with one culture vessel

 As an overview of all subunits at fermentor systems with 2…4 culture vessels

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 DCU3 systems available from about April 2002 on and as far as implemented).

 Via the direct function key CHANGE UNIT

Menu „Main“: Direct access to the main menus of subunits at fermentors with 2..4 culture vessels:

Example: BIOSTAT

®

B-DCU twin Example: BIOSTAT

®

B-DCU quattro

 The touch key „All vessel“ can be used to return to the overview display of all units.

The direct function key CHANGE UNIT cyclically switches over the displays of the main menus of all

units and the individual subunits:

 All vessels  vessel 1  vessel 2  (vessel 3, 4, if available)  all vessels

Operators 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 UNIT



.....

Operators Handbook DCU3 – System

3., Function Selection and Inputs

BAEDCU3 - Rev. 4.6 - 0504 3 - 7

3.1.5 Direct Function Keys

The direct function keys on right hand of the „Touch Terminal“ allow for direct access to the system:

SHUT DOWN : Pressingthis key sets all analog and digital outputs into a safe state. An active

SHUT DOWN state is indicated by lighting LED in the key. Repeatedly pressing the key

cancels (releases) the SHUT DOWN state and the system returns to its previous state.

ACK : If an alarm message occurs, a red LED in the ACK - key lights. Pressing the ACK - key then

enables the alarm menu on the display.

REM : Pressing the REMote control key allows for the transmission of data from the host to the

DCU system. Effective only if a host computer is connected to the DCU-system.

CHANGE UNIT : Switching-over of the operating 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 inputs, shown here for the temperature setpoint:

1. Press either the touch-key „Temp“ in the work-

ing area of the „main“ menu or the key “SETP”

in the menu TEMP Control Loop

A touch key pad fades in for data input.

2. Enter the new setpoint. For this consider the

permissible setpoint range, as indicated.

3. At erroneous inputs delete the entry with CAN-

CEL and enter the correct numbers.

4. Confirm the input with the „Ok“-key.

5. The system closes automatically the touch key

pad. The new setpoint is displayed.

 Input of operating mode, i.e. controller modes:

1. Press the touch key „MODE“;

a window with the selectable modes fades in.

2. Press the touch key of the intended mode, i.e.

„off“.

3. At selection of a wrong mode, delete with CAN-

CEL and select again the correct mode

4. The selection window closes and the display

shows the new mode.

Operators Handbook DCU3 – System

3., Function Selection and Inputs

BAEDCU3 - Rev. 4.6 - 0504 3 - 8

 Input of text:

1. Enter the text with a max. number of letters

(Range).

2. At wrong inputs delete the entry using the „<-“

key or CANCEL.

3. Confirm the Entry with „Ok“. The system closes

the keypad and displays the text.

 Selection boxes (slider): The slider can be moved as follows:

1. Pressing the arrow key

2. Moving the white zone within the slider

3. Pressing the shaded zone at the relative posi-

tion of the table, which should be 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 is

locked. This locking of an entry against inputs is indicated on the „OUT“ key. The letters

then are displayed in black & white dithering („light“).

3.2.2 Password - System

System settings and functions, that are restricted for use by authorized personnel only, are protected

by a password. Among others these are, for instance, the setting of controller parameters (such as

PID), the setting of interface parameters and the manual operating mode.

 For more detailed information refer to section “Main function “Password””.

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Sartorius DCU 3 Operator's Handbook Manual

Sartorius DCU 3 Operator's Handbook Manual

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