Operating Manual
2018-03-28
Touch Screen Software V 3.0
for benchtop bioreactors Labfors 5 and Multifors 2
Dok-ID: 77085 - Original - V.01.01
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Touch Screen Software V 3.0 - for benchtop bioreactors Labfors 5 and Multifors 2
Table of Contents
28 March 2018 Page 1 of 179
1 Screen, Menu Navigation and Control Elements................5
1.1 Screen Areas .................................................................6
1.2 Control Elements ...........................................................9
2 Main Menus...........................................................................13
2.1 Main – Parameter Display All Bioreactors ...................13
2.2 Batch – Start Menu ......................................................16
2.3 Controller – Value Display ...........................................17
2.4 Cascade.......................................................................19
2.5 Trends – Trend Lines...................................................20
2.6 System – System Settings...........................................22
2.6.1 Statistics – Software Communication with
Bioreactor Hardware ....................................24
2.6.2 Update – Installing a Software Update.........24
2.7 Alarms – Parameter Alarms, User Alarms, System
Alarms..........................................................................26
2.7.1 Parameter Alarms ........................................28
2.7.2 System-Alarm “Difference in board
configuration”................................................28
3 Submenus.............................................................................30
3.1 Valves – Digital Controller Outputs..............................30
3.1.1 Switching Digital Outputs Manually..............34
3.1.2 Switching Back to Automatic Mode..............36
3.2 Security – User Management ......................................37
3.2.1 User Levels...................................................38
3.2.2 Access Authorisations of User Groups ........40
3.2.3 Login – Logging on to the System................44
3.2.4 Logout – Logging off the System .................46
3.2.5 Change Password ........................................47
3.2.6 New User – Adding a New User ..................48
3.2.7 Remove User – Deleting a User ..................51
3.2.8 Edit User – Editing User Settings.................52
3.2.9 Set / Delete Default User – Setting or Deleting
an automatic User Login ..............................54
3.3 Settings – Basic Unit Settings......................................56
3.3.1 IP Settings – Network Settings.....................58
3.3.2 Change Time – Changing Date and Time....60
3.3.3 Backup – Saving Data..................................62
3.3.4 Restore – Restoring Saved Data or Restoring
Factory Settings ...........................................64
3.3.5 Export Logs – Exporting Log Files ...............67
3.3.6 Balance Settings ..........................................68
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3.4 Wipe Screen – (Temporarily) Locking the Screen.......70
3.5 Shutdown – Shutting Down the System.......................71
4 Recipes..................................................................................73
4.1 Save Recipe – Saving a Recipe ..................................74
4.2 Load/Start Recipe – Loading and a Recipe .................76
4.3 Delete Recipe – Deleting a Recipe..............................79
5 Parameters............................................................................81
5.1 Temp............................................................................81
5.2 Stirrer ...........................................................................81
5.3 pH.................................................................................82
5.4 pO2 ..............................................................................83
5.5 Antifoam .......................................................................84
5.6 Level.............................................................................84
5.7 Feed .............................................................................84
5.8 Feed 2 + Feed 3...........................................................84
5.9 Weight..........................................................................84
5.10 Flow..............................................................................85
5.11 GasMix .........................................................................85
5.12 GM Flow.......................................................................87
5.13 Air Flow ........................................................................87
5.14 O2 Flow........................................................................88
5.15 N2 Flow ........................................................................88
5.16 CO2 Flow .....................................................................89
5.17 Exit CO2 and Exit O2...................................................89
5.18 Light .............................................................................90
5.19 OD................................................................................91
5.20 Capacitance .................................................................92
5.21 Conductivity..................................................................92
5.22 Redox...........................................................................93
5.23 pCO2............................................................................94
5.24 JTemp ..........................................................................94
6 Parameter Options ...............................................................95
6.1 Setpoint ........................................................................97
6.1.1 Setting Setpoint Values, Switching
Parameters ON / OFF ..................................99
6.2 Calibrate.....................................................................105
6.2.1 Calibration Menus METTLER Sensors ......106
6.2.2 Calibration Menu HAMILTON Sensors ......110
6.2.3 pH Sensor Calibration ................................113
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6.2.3.1 Calibrating a METTLER pH
Sensor.........................................114
6.2.3.2 Recalibrating a METTLER pH
Sensor.........................................117
6.2.3.3 Calibrating a HAMILTON pH
Sensor.........................................118
6.2.3.4 HAMILTON pH Sensor Product
Calibration...................................121
6.2.4 Calibrating all pH Sensors..........................124
6.2.4.1 Calibrating all METTLER pH
Sensors.......................................125
6.2.4.2 Calibrating all HAMILTON pH
Sensors.......................................129
6.2.4.3 Error Codes Calibrating all
HAMILTON pH Sensors..............133
6.2.5 pO2 Sensor Calibration...............................134
6.2.6 Polarising the pO2 Sensor (METTLER)......135
6.2.6.1 Calibrating a METTLER pO2
Sensor.........................................136
6.2.6.2 Calibrating a HAMILTON pO2
Sensor.........................................139
6.2.1 Calibrating all pO2 Sensors........................142
6.2.1.1 Calibrating all METTLER pO2
Sensors.......................................142
6.2.1.2 Calibrating all HAMILTON pO2
Sensors.......................................144
6.2.1.3 Error Codes Calibrating all
HAMILTON pO2 Sensors ...........147
6.2.2 Calibrating the Zero Point of the Turbidity
Sensor Optek-ASD.....................................148
6.3 PID (Control)..............................................................150
6.3.1 Explanations of PID Control .......................152
6.3.2 Changing the PID Controller Settings ........154
7 Cascade Control.................................................................155
7.1 Setting a Cascade .....................................................157
7.2 Deleting a Cascade ...................................................161
7.3 Negative Function of a Cascade................................162
7.4 Special Configurations...............................................163
8 Pumps & Options...............................................................164
8.1 Calibrating a Pump ....................................................165
8.2 Resetting the Pump Counter to Zero.........................169
8.3 Automatically Filling/Emptying Pump Hoses .............171
9 Starting & Stopping the Bioreactor(s) .............................173
9.1 Starting a Bioreactor ..................................................174
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9.2 Stopping a Bioreactor.................................................176
9.3 Starting all Bioreactors...............................................177
9.4 Stopping all Bioreactors .............................................179
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Screen, Menu Navigation and Control Elements
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1 Screen, Menu Navigation and Control Elements
Most of the figures in this manual showing the various menus, dialogue
boxes and tab pages of the touch screen software reflect the
view of a user with the user authorisation level of Technician.
For further information about user levels and access authorisation
see chapter “Security – User Management”, “User Levels”.
The figures in this manual showing main menus always show the
maximum possible number of controllable bioreactors (= 6) and are
from the touch screen software for Labfors 5.
The touch screen software for Labfors 5 and Multifors 2 is identical
except for the different names of the equipment displayed in the
upper left corner of the screen.
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1.1 Screen Areas
The screen is divided into the three sections:
1 Header
2 Main are
3 Footer
Header
shows (from left to right): name of the equipment, selected bioreactor
e.g. Bioreactor A selected, login-status, e.g. Logged in as Technician
and the time.
Two opposing vertical arrows in the header signalise that an external
software like e.g. eve® has access to the OPC XML DA server
2
3
1
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of the touch screen software. They are flashing while data is trans-
mitted
Main area
shows main menus and submenus, e.g. main menu Batch, see figure
above.
Inputs are made exclusively in the main area. I.e. you press buttons
or input fields to select bioreactors or to call up menus and
dialogue boxes.
The lower section of the main area shows a selection bar for individual
bioreactors which are available for selection. The bioreactors
are represented by a culture vessel symbol.
Depending on the configuration of the system, up to six bioreactors
(= culture vessels) may be connected. This equates to six Labfors
5 basic units with one culture vessel or max. three Multifors 2
basic units with two culture vessels each.
One operating unit with touch screen software can be used to control
up to six bioreactors. I.e. one basic unit serves as the master
unit and can control up to five more basic units of the Labfors 5 bioreactor
and up to two more basic units of the Multifors 2 bioreactor.
These basic units are referred to as satellite units.
Bioreactors 1 to 6 correspond to the bioreactors A to F in the selection
bar. They can be operated independently of each other.
Available bioreactors are shown in dark grey colour with grey content,
non-available bioreactors are in light grey colour without content.
A selected bioreactor is shown in orange colour (from left to
right) with grey content.
A running bioreactor (operating status running) is shown with green
content.
ALL can be used to select all available bioreactors simultaneously.
Footer
comprises 7 tabs which provide access to the 7 main menus.
The tabs are displayed with a grey background. A selected tab is
shown light grey.
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Screen, Menu Navigation and Control Elements
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The following main menus are available (from left to right):
 Main: shows parameters and values for the available bioreactors.
If a single bioreactor is selected, its available pumps are
also visible here.
 Batch: this is where bioreactors (fermentation/cultivation processes)
are started and stopped, and where sensors and
pumps are calibrated. Depending on the access authorisations,
it may also be possible to store, upload or delete recipes
(fermentation logs).
 Controller: shows parameters for the selected bioreactor and
offers the option of changing values.
 Cascade: allows to set up a serial, parallel or parallel serial
(mixed) cascade control of one or several parameters.
 Trends: shows trends in the parameters, time span between
15 min. and 2 days.
 System: provides access to the submenus VALVES, SECURITY,
SETTINGS, WIPE SCREEN and SHUTDOWN
 Alarms: shows parameter alarms, user alarms and system
alarms
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1.2 Control Elements
The following control elements are used in the touch screen soft-
ware:
Buttons
Depending on the selected main menu or submenu and access
authorisations, various buttons may be visible and available.
Pressing a button either opens a sub menu, or a dialogue box or a
tab page.
Enabled buttons are white in colour, disabled buttons are grey in
colour.
Example: Start/Stop of the bioreactor (fermentation/cultivation pro-
cess).
Buttons, which are intended as the next logical step in the procedure,
are shown in orange colour.
Example: Confirmation of an entry and/or starting/ending a process
with OK.
Dialogue boxes and tab pages
A dialogue box may contain further buttons, input fields or view
boxes and tabs. A dialogue box may also contain instructions,
notes, warnings or general information
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Example: Confirmation dialogue box with confirmation prompt.
Example: pH properties dialogue box with tabs which lead to the
different parameter options.
Pressing a tab leads to access of the respective option for the selected
tab page. The tab for a selected tab page is displayed with a
white background.
Depending on the parameter and the access authorisations there
may be more or less available options for a parameter.
Input fields and view boxes
They are included in various menus, dialogue boxes and tab
pages. They either require the inputting of a numerical or an alphanumerical
value or show these values.
Example: Calibrate pH probe dialogue box with input fields for calibration
points and view boxes Sensor data.
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Numeric keypad and alphanumeric keyboard
Numerical values are entered using a numeric keypad (figure on
the left). Alphanumerical values are entered using an alphanumeric
keyboard (figure on the right).
After pressing an input field, the appropriate pad/board appears.
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ON / OFF switch
The ON / OFF switch is used in order to switch a function on or off.
 ON: the switch is in orange colour
 OFF: the switch is in white colour
Example: ON/OFF switch to enable/disable Edit function in main
menu Cascades
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2 Main Menus
2.1 Main – Parameter Display All Bioreactors
After a system start the main menu Main opens automatically. This
is where the parameters for the available bioreactors are listed with
their current values. Also the operating statuses of the bioreactors
(running / stopped) are visible and the parameter alarms are signalled
here.
The quantity and type of parameters differ depending on the system
configuration but remain the same for each individual available
bioreactor.
Parameter values and the symbol of a selected bioreactor are displayed
in orange.
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A large illustration of the bioreactor which has been selected via
the selection bar is displayed on the right-hand section of the
screen. All pumps of the selected bioreactor are displayed above it
as buttons.
The following four pumps are available by default:
 Acid
 Base
 Feed
 Antifoam
INFORMATION
If all bioreactors (ALL) are selected, the message Please select
the bioreactor to view the pumps appears instead.
The delivered volume (in mL) of a calibrated pump is continuously
shown while the bioreactor is running. This numerical value is displayed
on the appropriate pump button, as the example for the
Feed pump shows on the left.
After pressing one of the four buttons a dialogue box, e.g. Feed
pump properties appears.
This is where the number of rotations of the selected pump can be
reset to zero.
The pump factor calculated during pump calibration is also visible
and can be changed manually here.
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Parameter alarms which have not been confirmed are signalled in
the corresponding bioreactor column with a warning symbol above
the actual values. A detailed list of parameter alarms can be found
in the main menu Alarms.
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2.2 Batch – Start Menu
The main Batch menu is divided up into groups with various buttons
which correspond to the function of the group:
 Preparation: to calibrate individual or all pH and pO2 sensors
and automatic and to simultaneously fill or empty all pump
hoses.
 Calibrate Pumps: to start and stop pump calibration. Pumps
can only be calibrated individually for each bioreactor.
 Bioreactor Operation: to start and stop one bioreactor (fermentation/cultivation),
several bioreactors or all bioreactors
 Recipes: to load, save and delete recipes.
Depending on access rights of the operator, selection of the bioreactor(s)
and operating status of an individual or several bioreactors
more or less functions are available.
Detailed descriptions of each function can be found in the appropriately
named chapters in this manual.
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2.3 Controller – Value Display
The main menu Controller shows current values, setpoint values
and controller outputs for the parameters of a selected bioreactor.
This menu is not available when all bioreactors (ALL) are selected.
Settings for parameters can be changed here.
 Parameter: lists the available parameters. Touching the desired
parameter button opens its setting menu, see chapter
“Calling up Parameter Options”.
 Value: displays the actual parameter values
 Units: displays the units of the parameters
 Setpoint: to enter/change setpoint values of parameters
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INFORMATION
When the bioreactor has been stopped, setpoint values in the
Controller menu are overwritten with the setpoint values set in the
start dialogue. See the chapters “Setpoint” and “Setting Setpoint
Values, Switching Parameters ON / OFF” for details.
 Cascade: indicates, whether and how cascade control is active
and which process parameters are used. Settings for a
cascade are made in the main menu Cascade. A detailed description
about cascade control can be found in the chapter
“Cascade Control”.
 Output: displays the controller output for a parameter in %
when a bioreactor is running. A switched off parameter is displayed
as OFF. When the bioreactor has been stopped, all its
parameters are automatically switched off. Parameters can be
switched on or off here whilst a bioreactor is running by touching
the controller output (displayed value OFF or %). This is
only possible, if the automatic mode is set in the Setpoint option
of the parameter concerned.
 V-Bar (vertical bar): shows a graph comparing the current
value, set value and alarm limits:
 Grey continuous marking: set setpoint value
 Yellow marking: set alarm value (lower alarm / upper
alarm).
 Red marking: set critical values (lower critical / upper crit-
ical).
 Green bar: current value is within the alarm limits.
 Yellow bar: current value has exceeded the upper alarm
value or dropped below the lower alarm value.
 Red bar: current value has exceeded the upper critical
value or dropped below the lower critical value.
 O-Bar (controller output bar): shows a graph of the current
controller output (%). Parameters which are controlled on two
sides (e.g. pH and temperature) are shown as a two-part bar.
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2.4 Cascade
The main menu Cascade provides the option of setting up a serial,
parallel or mixed cascade control of a parameter. This function is
mainly used for pO2 regulation.
The cascade settings are made in the left-hand section of the
screen and the main section presents these schematically. The
individual process parameters can be added to a cascade by dragging
& dropping them.
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2.5 Trends – Trend Lines
The touch screen operating unit keeps the current parameter values
in a buffer and continuously charts them in the main menu
Trends. This data can neither be archived nor edited or exported.
The main menu Trends serves to provide quick information on the
progress of the cultivation only. This menu is not available when all
bioreactors (ALL) are selected.
However, the data can be archived on computer connected via network
using eve®.
The parameters for the selected bioreactors are listed on the righthand
side of the screen. The ON/OFF switch next to each parameter
allows to activate/deactivate the display of its trend line in the
main area of the screen.
All trend lines are normalised to the value range of the respective
parameter. The maximum value (= 100 % of the normalised scale)
is located on the top of the diagram, the minimum value (= 0 % of
the normalised scale) on the bottom. When a parameter is selected
from the list, the labels on the Y axis will switch to the value range
of the selected parameter. When Common is selected, the labels
on the Y axis are reverted to the normalised scale.
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The sideways spread of the diagram can be selected via the buttons
below the diagram:
 15 min and 30 min: 15 and 30 minutes
 1 h, 6 h and 12 h: 1, 6 and 12 hour(s)
 1 d and 2 d: 1 and 2 day(s)
The Background button allows to change the background colour
of the diagram display (white, grey and black).
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2.6 System – System Settings
The main menu System shows the following:
 Serial number
 Software version
 IP address of the system(s)
 Firmware version
 Manufacturer’s internet address (Domain)
Two buttons are situated in the upper right side of the screen:
 Update: for software updates. This button is only available on
user level Administrators and above. For details about this
function see chapter “Update – Intalling Software Updates”
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 Statistics: enables viewing some statistics of the software
communication with the controller, i.e. the hardware of the bioreactor(s).
The function is only used for fault diagnosis for the
technical support from the manufacturer and is available on
user level Technicians and above.
The menu has 5 buttons which access the submenus with various
functions:
 VALVES: displays the status of the digital outputs.
INFORMATION
In normal mode and with the default factory settings, all digital
outputs are set to Auto mode (automatic mode) and should not be
changed.
 SECURITY: for system log-in and log-off, passwords and user
management.
 SETTINGS: for the system and basic settings of the bioreac-
tor(s)
 WIPE SCREEN: to lock the screen for 20 seconds, e.g. for
screen cleaning
 SHUTDOWN: to shut down and switch off the system.
A detailed description of the submenus can be found in the appropriately
titled chapters.
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2.6.1 Statistics – Software Communication with Bioreactor Hardware
The Statistic function (Statistics button) in main menu System enables
viewing some statistics of the software communication with
the controller, i.e. the hardware of the bioreactor(s). This function is
only used for fault diagnosis for the technical support from the
manufacturer.
2.6.2 Update – Installing a Software Update
The Update function in main menu System enables to install software
updates from a USB stick onto the system.
INFORMATION
It is recommended to create a backup copy on an USB stick of
the existing system configuration using the Backup function in
submenu Settings before installing the software update.
ATTENTION
The existing configuration is preserved in the best possible way
when performing a software update. In individual cases, e.g. for
customized equipment, it may be necessary to make specific adjustments
after the update. Therefore, always consult the Infors
service or an authorised service partner before installing an up-
date.
Proceed as follows:
Procedure 1. Use the special cable provided with the equipment and connect
it to the appropriate connector (see figure on the left) on
the rear side of the operating panel.
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2. Connect the USB stick.
3. Log on to the system on user level Administrator.
4. Call up main menu System.
5. Press Update.
The Confirmation dialogue box appears with:
 Information: The system will be updated.
 Instruction: Press OK to confirm.
 OK: to execute the update
 Cancel: to cancel and close the dialogue box without
changes.
6. Press OK.
Progress is continuously displayed on the screen.
Once the update is completed, the system is restarted with its
standard settings and the message Configuration files from
previous version detected! in main menu Alarms indicates that
configuration data of a previous version were detected.
Restoring individual settings
The Restore function is used now, to restore the previous individual
bioreactor setttings.
Proceed as follows:
Procedure 1. If applicable, connect other USB stick with the previously
saved data via Backup function..
2. In main menu System, call up submenu Settings and press
Restore.
3. Select the file “ModifiedConfiguration_number_of_previous
version”. Alternatively, select desired backup data from USB
stick.
4. Continue as described in chapter “Restore – Restoring Saved
Data or Factory Settings”.
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2.7 Alarms – Parameter Alarms, User Alarms, System Alarms
The main menu Alarms lists the parameter alarms for all running
bioreactors by time of occurrence. The following user alarms and
system alarms are shown here, too:
 Password Expiry
 Difference in board configuration:
INFORMATION
A backup of each controller board configuration of each satellite
is stored in the touch screen. This alarm will occur after a firmware
update / exchange of the controller board, if there are differences
between the backup and the current configuration.
 System restarted after power failure
 Invalid modbus map for Parameter xy
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INFORMATION
This alarm can only occur if modbus settings were modified. Modbus
settings can only be modified on user level Service.
A parameter alarm is signalled by the Alarm tab flashing light red
and dark alternately.
The screen contains the following columns:
 Bioreactor: displays the bioreactor (A to F) to which the parameter
alarm refers.
 Description: describes the alarm
 Start: shows the date and time when the alarm started.
 End: shows the date and time when the parameter alarm
ended.
 Confirmed: indicates confirmed and not confirmed alarms.
Not confirmed alarms are confirmed by pressing Confirm.
Confirmed alarms are displayed with the date, time and user.
Not confirmed parameter alarms are also signalled in the main
menu Main in the corresponding bioreactor column with a warning
symbol.
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2.7.1 Parameter Alarms
A parameter alarm occurs as soon as the current value of a parameter
is outside the set alarm tolerances.
A parameter alarm is triggered as soon as a value drops below the
lower alarm value or exceeds the upper alarm value.
The example in the figure on the left shows: Stirrer: Lower alarm
(153 < 200). I.e. for biorecter A, the current value for parameter
Stirrer (=153 rpm) is below the lower alarm value (= 200 rpm)
INFORMATION
The values in brackets always refer to the setting of the alarm
value or critical value compared with the current alarm value or
critical value.
2.7.2 System-Alarm “Difference in board configuration”
A backup of each controller board configuration of each satellite is
stored in the touch screen. If there are differences between the
backup and the current configuration after a firmware update / exchange
of the controller board respectively the touch screen, the
alarm will Difference in board configuration occur. This signifies
that the configurations do not correspond with each other.
To enable to select the appropriate configuration, the Synchronize
differing board configuration appears and is enabled in the Controller
Board Configuration section of the main menu Settings.
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After selection of this function (pressing the button), the menu appears
with the two following options:
 Use current board configuration: to replace the bakcup in
the touch screen with the current configuration of the controller
board.
This is appropriate after exchange of a touch screen.
 Use stored board configuration: to overwrite the configuration
of the controller board with the configuration from the
backup.
This is appropriate after a firmware update, respectively replacement
of a controller board.
The alarm disappears as soon as the function is executed.
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3 Submenus
3.1 Valves – Digital Controller Outputs
The submenu VALVES displays the digital outputs and inputs of
the controller in the basic unit of the equipment. The overview is
predominantly used for fault diagnosis.
In normal mode and with the default factory settings, all digital outputs
are set to Auto mode (automatic mode) and should not be
changed.
The menu has two parts and is divided into several columns:
Left Side: Category
 All: To select display of all digital outputs (an inputs)
 Outputs: To select display of all digital outputs
 Inputs: To select display of all digital inputs
Main area
 Bit: Channel number
 Name: Designation
 Mode: Mode: A distinction is made between two modes:
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 Auto: automatic mode = automatic switching
 Manual: manual mode = outputs are forced. I.e. the automatic
switching is thus disabled.
 Set: Switching status of the digital output. A distinction is
made between two statuses:
 OFF: output is switched off.
 ON: output is switched on.
 ReadB (ReadBack): electronic feedback channel which confirms
the change in status.
 OFF: Readback is switched off
 ON: Readback is switched on
INFORMATION
If the electrical connection is faulty, it is displayed as FALSE.
 Back: To get back to the main menu System.
The following table contains an overview and shows the general
significance of the listed digital outputs.
Note the following points:
 The outputs Bit 0 – 8 and 13 are reserved
 The outputs Bit 0 – 4 and 13 are always present
 The outputs Bit 5 – 8 are only functional, if the appropriate options
of the equipment are present with valves
 The outputs Bit 9 – 12 as well as 14 and 15 are spare outputs.
They are only used for special applications or, if the appropriate
option of the equipment is present.
INFORMATION
Depending on the equipment’s configuration, not all outputs can
be manually operated. I.e. although the output can be set to manual
mode, switching between ON/OFF will have no effect.
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Bit Name (designation) Meaning
0 STIR1 Stirrer1
Labfors 5 Lux LED Flatpanel and Multifors 2 Cell: not relevant
1 STIR2 Stirrer1
Labfors 5 Lux LED Flatpanel and Multifors 2 Cell: not relevant
2 HEAT Heating
3 COOL Cooling
4 CIRC Circulation pump
Multifors 2: not relevant
5 V-N2 N2 output (N2 input valve into vessel)
6 V-AIR Air output (air input valve into vessel)
7 V-O2 O2 output (O2 input valve into vessel)
8 V-CO2 CO2 output (CO2 input valve into vessel)
9 DO-A 24 V output
10 DO-B 24 V output
11 DO-C 24 V output
12 DO-D 24 V output
13 GCOOL Exit gas cooler valve
14 OC-A Open collector output / reserve
15 OC-B Open collector output / reserve
1)
Used only for special configurations
The following outputs are only present and visible, if a Labfors 5
bioreactor is configured for operation and control of the CIP/SIP
unit LabCIP.
Bit Name (designation) Meaning
24 V601 Solenoid valve (NC) / Water inlet
25 V602 Solenoid valve (NC) / CIP/SIP compressed air inlet
26 V603 Solenoid valve (NC) / Exit gas
27 V604 Solenoid valve (NC) / Compressed air to semi-automatic push
valve 612 (exit gas cooler)
28 V605 Peristaltic valve (NC) / CIP/SIP circuit
29 V606 Peristaltic valve (NC) / CIP/SIP air inlet and venting
30 V607 Peristaltic valve (NC) / CIP/SIP emptying
31 V608 Peristaltic valve (NC) / CIP/SIP venting
32 V609 Peristaltic valve (NC) / CIP/SIP exit gas
33 V610 Peristaltic valve (NC) / CIP/SIP inlet air
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34 V611 Peristaltic valve (NC) / CIP/SIP emptying
35 Free1 Spare output
36 Free2 Spare output
37 Free3 Spare output
38 Free4 Spare output
39 Free5 Spare output
80 LA600 Levels sensor vessel
81 LA601 Level sensor CIP/SIP circuit
82 Switch Water leak detector (optional)
83 Free 1 Spare input
84 Free 2 Spare input
85 Free 3 Spare input
86 Free 4 Spare input
87 Free 5 Spare input
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3.1.1 Switching Digital Outputs Manually
If the user has the appropriate access authorisation (user level
Technician and above), the digital outputs can be switched to manual
for fault diagnosis (forced).
ATTENTION
Inappropriate switching of the digital outputs from automatic to
manual mode can cause the equipment to malfunction and result
in the risk of loss of property!
The following explains the procedure using the example of the
GCOOL output (exit gas cooler valve).
The initial position is: The output is switched off and in automatic
mode.
Initial position: The output is switched off and in automatic mode.
Proceed as follows:
Arbeitsschritte 1. Move the ON/OFF switch of the cooler to the left.
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The Warning dialogue box appears with:
 State of the valve will be changed from auto to manual:.
 Press OK to confirm
 OK: to execute switching
 Cancel: to cancel the procedure
2. Press OK.
Ausgang GCOOL schaltet in den manuellen Modus und
gleichzeitig wird der Ausgang forciert ausgeschaltet (Status in
Spalte Set = OFF).
The GCOOL output switches to manual mode and is therefore
forced switched off. (State in Set column = OFF ).
The GCOOL output can now be manually switched on:
3. Move the ON/OFF switch of the cooler to the right in the Set
column.
The GCOOL output remains in manual mode but is switched
on.
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3.1.2 Switching Back to Automatic Mode
To switch the GCOOL output back to automatic mode:
Procedure
1. Move the ON/OFF switch of the cooler to the right.
The GCOOL output switches back to automatic mode.
The output is in its original switching status; i.e. it is set to OFF
(Set column) in this example.
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3.2 Security – User Management
The submenu Security is used for logging on and off the system.
This is where users can also be added or deleted, passwords can
be issued and access authorisations can be assigned.
More or less buttons may be enabled in this menu depending on
the access authorisation of the registered user:
 Login/Logout: to log on to the system / to log off from the
 Change own password: to change the own password
 New User: to add a new user
 Edit User: to edit user settings
 Remove User: to delete a user.
 Set Default User/Clear Default User: to define/delete automatic
user login.
The different user levels, access authorisations and functions are
described in the following chapters.
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3.2.1 User Levels
The system has five user levels with different access authorisations.
The user levels are designated and defined as Groups.
Service: This user group has access to all system and bioreactor
settings. This user level is accessible for the manufacturer's (INFORS
HT) qualified service employees only and access for all
other users is blocked.
Administrators: This user group has access to basic system and
bioreactor settings. New users can only be added, altered and deleted
by users allocated to the user groups Service or Administrators.
The default setting for the login to the system is predefined as
Administrator.
ATTENTION
The Administrators user level provides access to important settings
for the bioreactor(s) and the system. Improper changes to
the settings can have a negative influence of the function of the
equipment and cause serious loss of property!
Technicians: This user group has limited access to system and
bioreactor settings. The default setting for the login to the system is
predefined as Technician.
User: This user group only has restricted access to the system.
The default setting for the login to the system is predefined as
User.
Guests: This user group has viewing authorisations only and no
access authorisations. Exception: users with this user level can
select trend lines in the main Trends menu to display or hide them,
change the background colour for the diagram display and select
the time range for the diagram display. This user level serves as
protection against unauthorised access to the system or unintentional
changes to settings.
This user level is set automatically as long as no user is logged on
to the system. This is indicated by the words Guest mode in the
header on the screen.
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The default password setting for the user groups Administrators,
Technicians and User is the same: qwertyuiop
INFORMATION
Passwords should be changed and managed by the authorised
person (users with user level Administrators) after commissioning
for the first time.
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3.2.2 Access Authorisations of User Groups
The following tables group the various functions of the touch
screen software with an indication of the access authorisations of
the user groups.
Key:
 V (view) = visible, function cannot be executed
Visible means that, depending on the function, the button or
the menu/dialogue can only be viewed.
 E (execute) = Visible and function can be accessed for execu-
tion
I.e. functions are executable
 Empty field = cannot be viewed and function cannot be exe-
cuted
Function User Groups
START / STOP BIOREACTOR(S) Guests User Technician Admin. Service
Start / Stop Bioreactor(s) V E E E E
Function User Groups
RECIPES Guests User Technician Admin. Service
Load/Start V V E E E
Save V V E E E
Delete V V E E E
Function User Groups
LAB CIP (Option CIP/SIP Unit ) Guests User Technician Admin. Service
LabCIP Settings V V E E E
Starting the LabCIP (Perform CIP/SIP) V E E E E
Function User Groups
PUMPS Guests User Technician Admin. Service
Calibrating pump(s) V E E E E
Resetting counter (Reset) V E E E E
Setting pump factor manually
(Pump factor)
V E E E E
Filling/emptying hoses automatically
(Fill/Empty Pumps)
V E E E E
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Function User Groups
PARAMETERS Guests User Technician Admin. Service
Setpoint V E E E E
Setting alarm and critical values
(Upper/Lower Alarm, Upper/Lower Criti-
cal)
V E E E E
Switching parameters on and off
(Output active ON/OFF)
V E E E E
Calibrating pH sensor(s)
(Calibrate pH / Calibrate All pH)
V E E E E
METTLER pH sensor : changing Slope
and/or Offset (Manual calibration mode)
E E E E
Calibrating pO2 sensor(s)
(Calibrate pO2 / Calibrate All pO2)
V E E E E
Special function USE AS SETPOINT in
calibration menu pO2
E E E E
Special function USE AS SETPOINT in
all calibration menus except pO2
E E
Calibrating the zero point of turbidity
sensor OPTEK (Calibrate OD).
V E E E E
Calibrate, all except pH and pO2 V E E
Calibrate, manually (manual calibration
mode), all except pH and pO2
E E
PID E E E
Options E
Function User Groups
CASCADES Guests User Technician Admin. Service
Setting a cascade V E E E E
Setting an advances (Advanced option) E1 E1 E
1)
For details refer to chapter “Setting a Cascade”.
Funktion User Groups
TREND LINES (Trends) Guests User Technician Admin. Service
Change display settings E E E E E
Function User Groups
ALARMS (Alarms) Guests User Technician Admin. Service
Confirming alarms V E E E E
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Function User Groups
SYSTEM Guests User Technician Admin. Service
Loading software update (Update) V V V E E
Viewing statistics of communication between
software and bioreactor hardware
(Statistics)
V V E E E
Function User Groups
DIGITAL INPUTS/OUTPUTS (System
/ Valves)
Guests User Technician Admin. Service
Manually switching digital inputs and
outputs
V V E E E
Function User Groups
SECURITY user management
(Security)
Guests User Technician Admin. Service
Logging on to the system (Login) E E E E E
Logging out from the system (Logout) E E E E
Changing password
(Change Password)
E E E E
Adding a new user (New User) V V E E
Deleting a user (Remove User) V V E E
Changing user settings (Edit User) V V E E
Setting automatic user login
(Set Default User)
V V E E
List of all users V V
Function User Groups
SYSTEM SETTINGS (System / Set-
tings)
Guests User Technician Admin. Service
Network settings
(Settings / IP Settings)
V V V E E
Changing date and time
(Settings / Change Time)
V V V E E
Saving data (Files / Backup) V V V E E
Restoring data (Files / Restore) V V V E E
Exporting log files (Files / Export Logs) V E E E
Settings in Service Menu
(Files / Service Menu)
E
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Function User Groups
SYSTEM SETTINGS / CONTROLLER
BOARD (System / Settings / Controller
Board Configuration)
Guests User Technician Admin. Service
Setting codes for input channels
(Input channel code)
V V E
Assigning/changing analogue outputs
(Analog Outputs Assign/Adjust)
V V E
Setting extended function codes for digital
outputs
(Extended Digital Output Function
Code)
V V E
Synchronising different configurations
of the controller board
(Synchronize differing board configura-
tion)
E E E
Modbus settings (Modbus mapping) V V E
Setting function codes for digital outputs
(Digital Output Function Code)
V V E
Settings for balances
(Balance Settings)
V V V E E
Function User Groups
TEMPORARY SCREEN LOCK (System
/ Wipe Screen)
Guests User Technician Admin. Service
Activating the temporary screen lock V E E E E
Function User Groups
SYSTEM SHUTDOWN Guests User Technician Admin. Service
Shutting down and switching off the
system
V E E E E
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3.2.3 Login – Logging on to the System
To log on to the system, proceed as follows:
Procedure 1. Call up the main menu System and press Security.
Submenu Security appears with:
 Login: Drop-down menu with users available by default with
factory settings (see picture above to the left):
 User
 Technician
 Administrator
 Other: for use by INFORS HT service employees only
 Default: Automatic user login without entering a password
if previously set using Set Default User
 Password: To enter the password
 Cancel: To cancel and close the menu without changes
 Login: To log on to the system (after password entry)
2. Select the desired user, e.g. Technician.
3. Press the input field Password.
The alphanumeric keyboard appears.
4. Enter the password and confirm with the OK key.
The input is saved; the alphanumeric keyboard disappears.
5. Press Login.
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The user is logged in as Technician. This is shown in the
header on the screen and the different functions are listed as
buttons in the Security menu. The buttons Change Password,
Logout, and Close are enabled on all user levels (except
for Guest).
6. Press Close.
Submenu Security disappears.
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3.2.4 Logout – Logging off the System
To log off from the system, proceed as follows:
Procedure 1. Call up main menu System and press Security.
Submenu Security appears.
2. Press Logout.
The user is logged off, menu Security appears for login.
3. Press Cancel.
Menu disappears.
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3.2.5 Change Password
Users of all user groups can change their own password. In order
to be able to change a password, the user must be logged on to
the system.
Proceed as follows:
Procedure 1. Call up submenu Security and press Change Password.
The Change password dialogue box appears with:
 Old Password: To enter the old password
 New Password: To enter the new password
 Confirm Password (minimum 8 characters): To confirm
then new password (min. 8 characters)
 OK: To confirm inputs, save changes.
This button is not enabled until the inputs have been
made.
 Cancel: To cancel without saving.
2. Press the input field Old Password.
The alphanumerical keyboard appears.
3. Enter the old password and confirm with the OK key.
Inputs appear as dots in the input field.
4. Proceed the same way with the new password in the input
fields New Password and Confirm Password.
All inputs are displayed as dots in the input fields.
5. Press OK.
The dialogue box disappears; the new password is saved.
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3.2.6 New User – Adding a New User
To add a new user to the user list, proceed as follows:
Procedure 1. Log on to the system on user level Administrator.
2. Call up the submenu Security and press New User.
The New User dialogue box appears with:
 Login: to enter a new user (name)
 Group: to select the user group
 New Password: to enter the password (min. 8 charac-
ters).
 Confirm Password (minimum 8 characters): to confirm
the password with min. 8 characters.
 Validity duration [days]: to enter the validity duration of
the password, choose “unlimited”, 30, 100 or 365 days.
 Expire: shows the selected validity duration of the pass-
word.
 Enable user: to activate/deactivate access authorisation
of the new user.
This function is switched on by default.
INFORMATION
The user has no access rights and no password can be defined, if
this function is deactivated.
 Logout if inactive: to switch on/off the automatic logout
when inactive after predefined duration.
 Logout after, min: to set the expiration time of the automatic
logout in minutes.
This input field is enabled only, when the function is
switched on.
 OK: to confirm entries.
This button is enabled only after input
 Cancel: to cancel without saving
3. Press Login.
The alphanumeric keyboard appears.
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4. Enter desired new user name, e.g. TEST, and confirm with the
OK key.
Input appears in the Login-field
5. Select the desired user group, e.g. Technicians
6. Press Password.
The alphanumeric keyboard appears.
7. Enter the desired password and confirm with the OK key.
The input appears as dots in input field.
8. Repeat the same procedure with the Confirm password input
field.
9. Select the validity duration of the password, e.g. validity.
10. Switch on access rights, if necessary.
11. If applicable, set automatic logout, if inactive:
Switch the function on and enter the desired time in minutes.
Once all settings are made:
12. Press OK.
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The dialogue box disappears, the new user is added and
shown in the user selection list.
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3.2.7 Remove User – Deleting a User
To remove a user from the, proceed as follows:
Procedure 1. Log on to the system on user level Administrator.
2. Call up submenu Security.
3. Select the user to be deleted in the user selection list. The fictitious
user TEST is used in this example.
4. Press Remove User.
The Confirmation dialogue box appears with:
 Information User “TEST” will be removed from user list:
 Instruction Press Yes to confirm operation.
 OK: To delete the user
 Cancel: To cancel without changes.
5. Press OK.
The dialogue box disappears, the user TEST is deleted from
the user selection list.
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3.2.8 Edit User – Editing User Settings
Edit User is used to change the following settings for an existing
user:
1) Assign new user group
See chapter “New User – Adding a New User” for details on
the procedure.
2) Change password
See chapter “Change Password” for details on the procedure.
3) Automatic user log-out when screen is inactive after a predefined
time in minutes has elapsed. The first user level Guests
is then set automatically.
To edit settings, proceed as follows:
Procedure 1. Log on to the system on user level Administrator.
2. Call up submenu Security.
3. Select the desired user from the user selection list, the fictitious
user TEST is used in this example.
4. Press Edit User.
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The Edit User dialogue box appears with nearly identical input
fields, view boxes, ON/OFF switches and buttons as in dialogue
box New User.
Exceptions:
 Login: This function is not enabled here
 Change …: To change the password. The two input
fields New Password and Confirm Password appear after
pressing this button.
5. Make required settings.
6. Press OK.
Settings are adopted; the dialogue box disappears.
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3.2.9 Set / Delete Default User – Setting or Deleting an automatic User Login
Set Default User is used to set an automatic user login. I.e. a user
can be defined who is then automatically logged on to the system
the next time it is switched on.
Clear Default User is used to delete the automatic login of a user.
Proceed as follows:
Procedure 1. Log on to the system on user level Administrator.
2. Call up submenu Security.
3. Touch the desired user in the user selection list. The fictitious
user TEST is used in this example.
4. Press Set Default User.
The selected user TEST is displayed in bold letters, the Set
Default User button is only visible, but not enabled anymore.
Changing the automatic user login
Another user can be defined here for automatic login.
When selecting the desired user in the list, the Set Default User
button is enabled again.
The new user is adopted for automatic user login after pressing
Set Default User.
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Deleting automatic user login
The automatic user login can be deleted here, too.
When selecting the defined user with the automatic user login setting
in the list, the Clear Default User button is visible and enabled
instead of the Set Default User button.
After pressing Clear Default User, the automatic user login is de-
leted.
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3.3 Settings – Basic Unit Settings
In the submenu Settings basic settings for the equipment are
made. Depending on the access authorisation, more or less buttons
are visible and enabled (for details refer to the tables in chapter
“Access Authorisations of User Groups”.
The figure above shows the menu on user level Administrator.
The menu is divided into three areas with the following functions:
Settings
 CIP/SIP Settings: only visible and enabled for Labfors 5 with
LabCIP. For details refer to the separate operating manual.
 IP Settings: for network settings
 Change Time: to set the date and time
Files
 Backup: to save data.
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 Restore: to restore and upload saved data.
 Service Menu: access only for qualified Infors service or licensed
dealer.
 Export Logs: to export log files.
Controller Board Configuration
 Input Channel Code: to set codes for input channels
 Analog Outputs Assign/Adjust: to assign/change analogue
outputs.
 Extended Digital Output Function Code: to set function
codes for extended digital outputs.
 Synchronize differing board configuration: to synchronize
differing board configurations.
INFORMATION
This button is only visible, if the appropriate alarm (Difference in
board configuration!) has been triggered and is displayed in main
menu Alarms after an update of the firmware / change of a control
board. For details refer to chapter “System Alarm Difference in
oard configuration”.
 Modbus mapping: for Modbus settings.
 Digital Output Function Code: to set function codes for digital
outputs.
 Balance Settings: for balance settings.
Back directs back to the main menu System.
INFORMATION
None of the functions concerning inputs and outputs, function
codes and modbus mappings are described in this manual.
These functions are only accessible for Infors service or Infors licensed
dealers.
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3.3.1 IP Settings – Network Settings
IP Settings is used to establish a network connection. This can be
performed either automatically or manually.
INFORMATION
This is only possible, if a network calble is connected.
This manual does not describe how to setup a network connection.
To call up the menu to make settings, proceed as follows:
Procedure 1. Log on to the system on user level Administrator.
2. Call up submenu Settings.
3. Press IP-Settings.
The Network Settings menu appears with:
 Obtain IP settings automatically: To set IP settings
automatically (default setting). Condition: a DHCP1
server is available in the network.
 Use the following IP settings: To use the following IP
settings.
Only after pressing this button, the following fields are en-
abled.
 IP address: Shows current IP address or to enter IP address
manually
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 Subnet mask: Displays default gateway or allows manual
input
 Default gateway: Shows default gateway or allows manuel
input
 „….connected“: Status message of the network connec-
tion.
INFORMATION
The status message …connected indicates that correct network
connection is established. If this is not the case (no signal), the
message „No active LAN connection“ appears.
 OK: To save inputs and close the dialogue box.
 Cancel: To close the dialogue box without changes.
1 ) Dynamic Host Configuration Protocol
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3.3.2 Change Time – Changing Date and Time
Change Time enables adjusting the system date and time to the
local conditions. The system is set for automatic synchronisation
with the time server ex-factory. I.e. the display is corresponding
with the selected time zone. Alternatively, these settings can be
manually adjusted.
To make settings, proceed as follows:
Procedure 1. Log on to the system on user level Administrator and call up
the submenu Settings.
2. Press Change Time.
The Change System time dialogue box appears with:
 ON/OFF switch Set time and date automatically is in position
ON
 Display (from left to right) for year, month, day, hours,
minutes and seconds.
 Dropdown menus for time zone and city: default = Europe
/ Zurich
 Cancel: To close the dialogue box without changes
 OK: To adopt inputs and close the dialogue box.
Changes with automatic adjustment
Proceed as follows:
Procedure 1. Select the time zone and city in the drop down menus.
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2. Press OK.
Settings are saved, the dialogue box disappears.
Manual changes
Proceed as follows:
Procedure 1. Switch automatic time and date setting off.
Input fields (from left to right) for year, month, day, hours,
minutes and seconds appear.
2. Press the desired input field(s), enter the value(s) via appearing
numeric keypad and confirm with the OK key.
Inputs are adopted.
3. Press OK.
Inputs are saved, the dialogue box disappears.
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3.3.3 Backup – Saving Data
The Backup function is used to save the entire settings of the touch
screen software and the control board of all connected bioreactors.
These data can be restored using the Restore function.
Note the following:
 Data can be saved on the internal memory or on a USB stick.
 A data backup is only executable when all bioreactors are
stopped, i.e. no fermentation/cultivation is running.
To execute a backup, proceed as follows.
Only when using a USB stick, otherwise go to step 2:
Procedure 1. Use the special cable provided with the equipment and connect
it to the appropriate connector (see figure on the left) on
the rear side of the operating panel and connect the USB
stick.
2. Log on to the system on user level Administrator, call up main
menu System and select submenu Settings.
3. Press Backup in the Files area.
The Confirmation dialogue box appears with:
 Information: You will be switched to backup mode
 Instruction: Press OK to confirm
 OK: To confirm switching to data backup mode
 Cancel: To close the dialogue box without changes
4. Press OK.
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The menu for data backup opens with:
 Select backup destination:
 local: To locally save the backup
 external: To save the backup externally on a detected
and connected USB stick.
 Create configuration backup: To create the backup
 Delete backup: To delete the backup
 Create factory settings from backup: To create factory
settings from the backup.
 Cancel: To leave the menu without changes
 OK: To save the backup and leave the menu.
5. Select the backup destination and press Create configuration
backup to create the backup.
6. Press OK to save the backup and leave the menu.
Deleting a backup
Pressing Delete backup opens a dialogue box with:
 Question: Are you sure to delete the selected backup?
 No: To cancel and close the dialogue box without changes
 Yes: To delete the backup and close the dialogue box
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If backup on USB stick:
7. Remove the USB stick and the cable.
3.3.4 Restore – Restoring Saved Data or Restoring Factory Settings
The Restore function enables to restore data, which have previously
been saved using the Backup function. Data will be uploaded
to the system again. It is also possible to restore factory settings
using this function.
INFORMATION
Factory settings usually represent the settings of the bioreactor/bioreactors
in as-delivered condition. In case of retrofitting of
one or several bioreactors, these settings can be updated, too.
Both is exclusively carried out by Infors Service or a licensed
dealer.
Note the following:
 Data are either restored from the internal memory or from a
USB stick, see chapter “Backup – Saving Data”.
 The Restore function is only executable when all bioreactors
are stopped, i.e. no fermentation/cultivation is running.
To execute the Restore function, proceed as follows:
Only when using a USB stick, otherwise go to step 2:
Procedure 1. Use the special cable provided with the equipment and connect
it to the appropriate connector on the rear side of the operating
panel and connect the USB stick with the saved date
(Backup data).
2. Log on to the system on user level Administrator, call up main
menu System and select submenu Settings.
3. Press Restore.
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The Confirmation dialogue box appears with:
 Information: You will be switched to restore mode
 Instruction: Press OK to confirm
 OK: To confirm switching to restore mode.
 Cancel: To close the dialogue box without changing the
mode.
4. Press OK.
The menu for data restoring appears with:
 Select Configuration for restore: To select the backup
data for restoring.
 Select factory settings: To select factory settings
 Cancel: To leave the menu without changes.
 OK: To load the selected backup and restore data.
Executing the backup for data restoring
Pressing Select configuration for restore changes the menu display
and shows with Select backup source the choice of the possible
data sources:
 local: internal memory
 xy (drive) / external: detected and recognised USB stick
 OK: To confirm selection
After selection of the data source, a dialogue box appears
with:
 Are you sure to restore the selected backup?
 No: To cancel and close the dialogue box without changes.
 Yes: To confirm restoration and start listing data for configuration
comparison.
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After confirmation via Yes, the screen changes and lists data for
configuration comparison.
 ≠ signifies a difference between Backup and current configu-
ration.
 = No difference between Backup and current configuration.
 +/- To open/close tree
 Show file / Show difference: To display file / difference
INFORMATION
This view for showing the difference within a file is for information
purposes and mainly foreseen for Infors service or licensed Infors
dealers. It shows the differences between the settings of the file
to restore and the currently used version in unified format (also
unidiff).
 Cancel: To cancel the backup process and leave the menu.
 OK: To execute the backup for restoring data.
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3.3.5 Export Logs – Exporting Log Files
The Export Log functions enables to save all log files (protocol
files) as well as alarms and error messages on a USB stick.
Note the following:
 A USB stick is needed for the export.
 Export is only executable when all bioreactors are stopped,
i.e. no fermentation/cultivation is running.
Proceed as follows:
Procedure 1. Use the special cable provided with the equipment and connect
it to the appropriate connector (see figure on the left) on
the rear side of the operating panel.
2. Connect the USB stick.
3. Log on to the system on user level Technician or Administra-
tor.
4. In main menu System, call up submenu Settings.
5. Press Export Logs.
Data export is started.
Once the export is finished, the Information dialogue box appears
with:
 Information Log files successfully exported to: xxxxx
 OK: To confirm and close the dialogue box.
6. Press OK.
The dialogue box disappears. The Zip file is stored on the
USB stick now.
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3.3.6 Balance Settings
This function is used to configure the connected balances. It is
possible to connect up to maximum 7 balances using the equipment
manufacturers switchbox.
Note the following:
The balance(s) must be configured as follows:
Baud rate 9600, 8 bits, no parity, 2 stop bits.
Proceed as follows:
Procedure 1. Connect the balance(s) or switchbox
2. Log on to the system on user level Administrator.
3. In main menu System, call up submenu Settings.
4. Press Balance Settings.
The menu Balance Configuration appears with:
 Information The balance(s) need to be configured for
9600 baud, 8 bits, no parity, 2 stop bits.
 Dropdown menu balances connected: to select number
of connected balance(s)
 None: no balance
 Single: one balance (without Switchbox)
 Infors SwitchBox
 7 dropdown menus which are enabled, once one option
has been selected.
 Back: to save settings and return to submenu Settings.
5. Select the desired balance(s).
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Dropdown menu(s) for selection of the balance type(s) connected
appear(s). The choice contains the following types:
none (no balance), Sartorius, Mettler, Kern KB und Ohaus
6. Select the balance type(s).
7. Press Back.
Settings are adopted, submenu Settings reappears.
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3.4 Wipe Screen – (Temporarily) Locking the Screen
The submenu Wipe Screen has one function only: It locks the
screen to prevent any inputs on the screen for 20 seconds. This
allows e.g. cleaning the screen for 20 seconds if required.
To activate the temporary screen lock, proceed as follows:
Procedure 1. In main menu System, press Wipe Screen.
The screen turns white, the remaining time is displayed in seconds
(Time left: xx seconds).
Once the time has elapsed, the last screen reappears auto-
matically.
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3.5 Shutdown – Shutting Down the System
The submenu Shutdown has one function only: it shuts down and
switches off the system.
The system can only shut down and switch off if all bioreactors
have been stopped.
Proceed as follows:
Procedure 1. Stop any running bioreactors by pressing Stop in the main
menu Batch, if necessary.
2. Call up the main menu System.
3. Press Shutdown.
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The Confirmation dialogue box appears with:
 Question Do you want to shutdown the system?
 OK: To shut down the system
 Cancel: To close the dialogue box without changes
4. Press OK.
The system shuts down and switches off.
INFORMATION
ALWAYS shut down the system first, only then switch the equipment
(Labfors 5 / Multifors 2) off at the main switch.
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4 Recipes
The various buttons for the Recipes function in main menu Batch
can be used to load and start, save or delete what are referred to
as recipes. This means all parameter settings (including cascade
settings) for a fermentation process can be saved and re-used for
recurring operating processes later.
INFORMATION
All parameter settings, cascade settings and calibration data of
sensors are saved. Pump calibration data are not saved. Calibration
data of sensors are not uploaded.
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4.1 Save Recipe – Saving a Recipe
Recipes can be saved when the bioreactor is running or stopped.
Recipes can only be saved individually for each bioreactor.
To save a recipe, proceed as follows:
Procedure 1. Log on to the system on user level Technician or above.
2. Select the desired bioreactor from the selection bar.
3. Call up main menu Batch and press Save Recipe.
The Save Recipe dialogue box appears with:
 Input field for the file name of the recipe being saved.
 OK: To save the recipe
This button is not enabled until a file name has been en-
tered.
 Cancel: To cancel the process without saving
4. Touch the input field.
The alphanumeric keyboard appears.
5. Enter the desired file name, e.g. BiorA and confirm with the
OK key.
The alphanumeric keyboard disappears
The file name is accepted, OK is enabled now.
6. Press OK.
The dialogue box disappears, the recipe is saved.
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Recipe file name used twice
If the file name for a recipe has been used twice, an Error dialogue
box appears with:
 The specified name for the recipe already exists
 Change the name for the recipe.
 OK: To close the dialogue box and enter the new name.
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4.2 Load/Start Recipe – Loading and a Recipe
A recipe has to be loaded for each individual bioreactor. One bioreactor
recipe can also be used for all other bioreactors.
All preparations for a fermentation/cultivaion process should be
made before loading and starting a recipe.
Loading recipe from bioreactor A for bioreactor A
The following example shows how a saved recipe of bioreactor A is
loaded to bioreactor A. Proceed as follows:
Procedure 1. Log on to the system on user level Technician or above.
2. Select the desired bioreactor from the selection bar.
3. Call up main menu Batch and press Load/Start Recipe.
The Load recipe on bioreactor A dialogue box appears with:
 Recipe name: lists all file names of saved recipes.
 Date of change: shows date and hour of the saved rec-
ipe(s).
 Next: to continue
This button is not enabled until a recipe has been se-
lected.
 Cancel: to cancel the process without saving
4. Select the saved recipe of bioreactor A.
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The selected recipe is displayed with an orange background.
5. Press Next.
The Load recipe on bioreactor A dialogue box changes views:
 Parameter: lists all the available parameters
 Output Active: to switch parameters on/off
 Setpoint: lists the saved parameter setpoint values of
the recipe
INFORMATION
This is where setpoint values can be subsequently changed here.
 OK: to start the bioreactor
 Cancel: to cancel the process without saving
6. If applicable, change setpoints and/or switch parameters
on/off.
7. Press OK.
The dialogue box disappears, bioreactor A starts.
Loading recipe from bioreactor A to bioreactor B
The recipe from one bioreactor (in this case bioreactor A) can also
be used for all other bioreactors (in this case bioreactor B). Proceed
as follows:
Procedure 1. Select bioreactor B from the selection bar.
2. Touch the Load/Start Recipe button in main menu Batch.
The Load recipe on bioreactor B dialogue box appears with
the same content as described for bioreactor A.
3. Select the saved recipe for bioreactor A.
4. Press Next.
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The Warning dialogue box appears with:
 Warning Recipe saved from a different bioreactor will be
loaded.
 Instruction Press OK to confirm.
 OK: to confirm execution and load the recipe.
 Cancel: to go back to the recipes selection.
5. Press OK.
The Load recipe on bioreactor B dialogue box changes the
view as described for bioreactor A.
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4.3 Delete Recipe – Deleting a Recipe
Recipes can only be deleted one by one. Recipes can also be deleted
during a running fermentation process.
To delete a recipe, proceed as follows:
Procedure 1. Log on to the system on user level Technician or above.
2. Select any bioreactor or all bioreactors from the selection bar.
3. Call up main menu Batch and press Delete Recipe.
The Delete Recipe dialogue box appears with:
 Recipe name column: file name of all saved recipes.
 Changed column: date and time of the saved recipes.
 OK: to delete the selected recipe
This button is not enabled until a recipe has been se-
lected.
 Cancel: to cancel the process without saving.
4. Select the desired recipe, e.g. Bior_A_Rezept1.
The selected recipe is displayed highlighted in orange.
5. Press OK.
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The Confirmation dialogue box appears with:
 Selected recipe will be deleted
 Press OK to confirm
 OK: to delete the recipe and close the dialogue box.
 Cancel: to cancel the process without saving.
6. Press OK.
The dialogue box disappears; the recipe is deleted.
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5 Parameters
The touch screen operating panel can display and control a maximum
of 24 parameters. Depending on the equipment and its configuration,
more or fewer parameters are visible and available in
the system.
The following describes first the default integrated parameters and
their function. It then describes the frequently used optional parameters
and their intended function.
Further application-specific parameters, whose configuration and
function differ from those described here, are available on request.
As a result of the various combination options, not all possible configurations
are described.
5.1 Temp
Measures and controls the temperature in the culture vessel.
Measurements are recorded by a platinum resistance temperature
sensor (Pt100).
Control range(s) vary depending on the equipment’s temperature
control system and can be found in the technical specifications of
the equipment’s operating manual.
5.2 Stirrer
Measures and controls the rotation speed of the stirrer shaft. This
depends on factors such as the type of vessel volume, drive system,
culture viscosity and number and kind of impellers and can be
found in the technical specifications of the equipment’s operating
manual.
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5.3 pH
Measures and controls the pH in the culture vessel. Control range:
pH 2 to 12. There are two systems to choose from for measuring
pH:
Analogue system
 Measuring range: pH 2 to 12
 Traditional pH sensor (potential measurement against refer-
ence)
 Manufacturer METTLER TOLEDO
Digital system
 Measuring range: pH 0 to 14
 Traditional pH sensor (potential measurement against reference)
with integrated electronics, of the type Easyferm Plus
ARC
 Manufacturer: HAMILTON
These pH sensors are preconfigured before dispatch by the
equipment manufacturer INFORS HT. Replacement sensors
of this type must be reconfigured before use!
pH is controlled as standard by adding acid and base via the two
digital peristaltic pumps Acid and Base. CO2 can also be used instead
of acid. In this case it is added via a magnetic valve or a
mass flow controller in the gas line. This configuration requires a
corresponding cascade control with a factory preset.
The activity of the pumps is time dependent. This means that they
always operate in start/stop mode at the same speed. Control is
made by a PID loop. A dead band can be used to prevent unwanted
rapid dosing.
Temperature compensation is a special function of the pH parameter
when using METTLER pH sensors. This function must be
switched on during fermentation so that the temperature dependency
of the measurement principle is corrected. For the digital
HAMILTON pH sensors, this function is integrated in the sensor.
INFORMATION
pH of liquids is also temperature dependent which is why the pH
also reacts on temperature changes when temperature compensation
is switched on.
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Details on technical data, use and maintenance of the pH sensors
can be found in the separate documentation of the sensor manu-
facturers.
5.4 pO2
Measures and controls the saturation of dissolved oxygen in the
(culture) medium. Control range: 0 – 100 %. There are two systems
to choose from for measuring pO2:
Analogue system
 Measuring range: 0 – 150 %
 Traditional amperometric/polarographic pO2 sensor.
 Manufacturer: METTLER TOLEDO
Digital system
 Measuring range: 0.05 % - 300 % air saturation
 pO2 sensor with integrated optoelectronics, type Visiferm DO
ARC
 Manufacturer: HAMILTON
These pO2 sensors are preconfigured before despatch by the
equipment manufacturer INFORS HT. Replacement sensors
of this type must be reconfigured before use!
In comparison, for example, with pH measurement which is calibrated
to absolute measurements, calibrating the oxygen measurement
is always performed to a relative reference point. To do this
the calibration is to 100 % relative oxygen saturation, generally determined
with air to a max. stirrer speed and maximum gassing
rate. The actual concentration of dissolved oxygen in mmol/l can
therefore differ for 100 % saturation depending on the process.
The PID controller output from pO2 is generally cascaded to other
parameters such as Stirrer, Flow, Feed or GasMix.
Details on technical data, use and maintenance of the pO2 sensors
can be found in the separate documentation of the sensor manu-
facturers.
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5.5 Antifoam
Measures the fill level or the foam formation and controls the addition
of antifoam reagent via the digital peristaltic pump Antifoam in
the culture vessel. The antifoam pump is activated when the antifoam
sensor comes in contact with foam.
The activity of the pump is time dependent. This means that it always
operates in start/stop mode at the same speed.
 The Dose time must be set in seconds instead of the setpoint.
 The Wait time must be set in seconds instead of setting an
alarm limit.
5.6 Level
Detects liquid in the culture vessel using a level sensor and regulates
the fill level using an assigned pump, depending on the con-
figuration.
5.7 Feed
The addition of the feed solution (feed) is regulated via the analogue
peristaltic pump Feed. Pump speed is adjustable and can be
set in steps of 0.1 % within a range of 0 % to 100 %.
2
5.8 Feed 2 + Feed 3
Regulates the addition of feed solution (feed) via the (optional) 5th
and 6th Feed 2 + Feed 3 peristaltic pumps. Pump speed is adjustable
and can be set in steps of 0.1 % within a range of 0 %
to 100 %.
2
5.9 Weight
Displays the measurement of a connected external scale.
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5.10 Flow
Measures and regulates the flow of two or more process gases in
the culture vessel via a single mass flow controller (thermal mass
meter with integrated control valve). The measurement system is
entirely electronic and the measurement is displayed according to
the present configuration in L/min or mL/min.
INFORMATION
The mass flow controllers are calibrated by the manufacturer at
their factory under standard conditions, which means at 1.013 bar
and 20 °C. For this reason for each gas flow rate, the standard
volumetric flow is given in L/min or mL/min.
If the parameter Flow is available this means that the individual
process gas lines are equipped with magnetic valves, which are
switched using the Gasmix parameter.
5.11 GasMix
Controls the oxygen concentration in the inlet air. This is achieved
by switching between air and oxygen or air and nitrogen for a
2-gas-mix system or air, oxygen and nitrogen for a 3-gas-mix sys-
tem.
Depending on the existing configuration this means that the relevant
magnetic valve is switched on or the individual gas flow parameters
are controlled.
Example
2-gas-mix system with air and oxygen, supplied via a magnetic
valve:
Settings
 cycle duration: 10 seconds
(visible in the input field Eval. Time (s) in the option PID of the
GasMix parameter)
 setpoint in the GasMix parameter: 20
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This means that:
 the magnetic valve for oxygen opens for 2 seconds
 the magnetic valve for process air opens for 8 seconds
Setpoint 100 ≙ 10 seconds
Setpoint 20 ≙ 2 seconds
INFORMATION
For this described configuration of the 2-gas-mix system with air
+ oxygen with two magnetic valves, the oxygen portion of the gas
mixture cannot fall below 20.95 %.
For a 3-gas-mix system the displayed value is the percentage of
oxygen in the gas mixture.
However, for entering the setpoint the following applies:
 -100 = only nitrogen ≙ 0 % O2 content
 0 = only air ≙ 21 % O2 content
 100 = only oxygen ≙ 100 % O2 content
If the parameter GasMix combined with the parameter GM Flow
and the parameters Air Flow, O2 Flow and/or N2 Flow is installed
Setpoint Parameter GasMix
Concentrationofoxygeningasmix
(displayedvalueofparameterGasMix)
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and configured, the specified parameters are preconfigured by the
equipment manufacturer in an advanced cascade for pO2 control.
ATTENTION
Changes to a cascade that has been preset by the equipment
manufacturer may cause controller errors!
5.12 GM Flow
Sets the gassing rate of the gas mixture (GasMix parameter). This
parameter can only be used and set in conjunction with the parameters
GasMix, Air Flow and O2 Flow and/or N2 Flow.
From the gassing rate of the gas mixture (GM Flow) and the setpoints
of the GasMix parameters the equipment calculates the flow
rates of the individual gases (e.g. Air Flow, O2 Flow etc.)
Only a setpoint input for the GM Flow parameter is required, the
values of the parameters specified above are automatically determined
and controlled.
ATTENTION
Additionally entering setpoints for individual flow parameters
when using the GM Flow parameter causes controller errors!
Should the flow parameters be individually controlled, the parameters
GM Flow and GasMix need to be switched off.
5.13 Air Flow
Measures and regulates the flow of air in the culture vessel via a
mass flow controller (thermal mass meter with integrated control
valve). The measurement system is entirely electronic and the
measurement is displayed according to the present configuration in
L/min or mL/min.
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INFORMATION
The mass flow controllers are calibrated by the manufacturer at
their factory under standard conditions, which means at 1.013 bar
and 20 °C. For this reason for each gas flow rate, the standard
volumetric flow is given in L/min or mL/min.
To specify the gassing rate independent of the used vessel size,
the specific gassing rate (also: vvm) is often used, at which the
standard volumetric flow is given in relationship to the culture volume.
Bioreactors for cultivating bacteria are generally designed for
a maximum specific gassing rate of 2 min-1. This means that the
maximum gassing rate is twice the maximum working volume per
minute. Cell culture bioreactors, in comparison, are usually designed
for a maximum specific gassing rate of 0.1 min-1.
5.14 O2 Flow
Measures and regulates the flow of oxygen in the culture vessel via
a mass flow controller (thermal mass meter with integrated control
valve). The measurement system is entirely electronic and the
measurement is displayed according to the present configuration in
L/min or mL/min.
INFORMATION
The mass flow controllers are calibrated by the manufacturer at
their factory under standard conditions, which means at 1.013 bar
and 20 °C. For this reason for each gas flow rate, the standard
volumetric flow is given in L/min or mL/min.
5.15 N2 Flow
Measures and regulates the flow of nitrogen in the culture vessel
via a mass flow controller (thermal mass meter with integrated control
valve). The measurement system is entirely electronic and the
measurement is displayed according to the present configuration in
L/min or mL/min.
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INFORMATION
The mass flow controllers are calibrated by the manufacturer at
their factory under standard conditions, which means at 1.013 bar
and 20 °C. For this reason for each gas flow rate, the standard
volumetric flow is given in L/min or mL/min.
5.16 CO2 Flow
Measures and regulates the flow of carbon dioxide in the culture
vessel via a mass flow controller (thermal mass meter with integrated
control valve). The measurement system is entirely electronic
and the measurement is displayed according to the present
configuration in L/min or mL/min.
INFORMATION
The mass flow controllers are calibrated by the manufacturer at
their factory under standard conditions, which means at 1.013 bar
and 20 °C. For this reason for each gas flow rate, the standard
volumetric flow is given in L/min or mL/min.
Labfors 5 Lux
If the parameter pCO2 is available, CO2 Flow is pre-configured for
control of the pCO2 parameter ex-factory.
5.17 Exit CO2 and Exit O2
These parameters measure the gas concentration of carbon dioxide
(CO2) and oxygen (O2) in the exit gas of the bioreactor and are
used for exit gas analysis. Usually these two measurements are
combined that is why both parameters are described here.
There are two systems to choose from for this (combined) measur-
ing:
Gas analysis device of the equipment manufacturer
 Measuring range CO2: 0 % - 10 Vol. % CO2
 Measuring range O2: 1 % - 25 Vol. % O2
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Gas sensor of the manufacturer BlueSens
a) Type BlueIn OneFerm
 Measuring range CO2: 0 % - 10 Vol. % CO2
Or 0 % - 25 Vol. % CO2
 Measuring range O2: 1 % - 50 Vol. % O2
b) Type BlueInOne Cell
 Measuring range CO2: 0 % - 10 Vol. % CO2
 Measuring range O2: 0.1 % - 100 Vol. % O2
Both types and all variants of these gas sensors of the manufacturer
BlueSens are combined CO2 and O2 sensors.
ATTENTION
Risk of damaging the gas sensor by operating outside of specifications!
The measurement cells of zirconium oxide-based gas
sensors (Infors Gas Analyser and BlueInOne Ferm) are damaged
when continuously operated with oxygen-free gas mixtures.
Therefore, only use gas sensors with galvanic measurement cells
(type BlueInOne Cell) when permanently operating with oxygenfree
gas mixtures.
Details on technical data, use and maintenance of the gas analysis
device or the gas sensors can be found in separate documenta-
tion.
5.18 Light
Labfors 5 Lux LED flat panel
Controls the light intensity of the LEDs on the irradiation unit. Setting
range: 0 %–100 %.
Settings can then be made in 0.1 % increments.
When using the optional light sensor, the Light parameter is calibrated
based on the absolute light intensity range of the built-in irradiation
unit. The value is indicated in µmol m-2 s-1.
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Also luminostat operation is possible, if the optional light sensor is
used. In this case, the Controlled function (check box) in parameter
option Setpoint must be activated to enable control.
The light intensity reaching the light sensor, is then used to define
a setpoint.
The controller modifies the light intensity of the irradiation unit so
that the same light intensity reaches the sensor allowing for varying
culture density conditions. In other words: the biomass always “receives”
the same quantity of light.
The bioreactor can also be converted for turbidostat operation on
request (Infors-Service). Here, the light intensity is recorded by the
separate parameter Light Sensor. A pump can also be cascaded to
this parameter in order to dilute the culture, if the measured light
intensity decreases. Over time, the biomass is adjusted so that the
average light intensity per biomass is kept constant.
5.19 OD
Is used to determine the turbidity of the culture by means of a
measuring system of the manufacturer Optek. The optical density
measurement can be used to draw conclusions regarding the biomass
concentration in the culture.
The measuring system comprises a sensor of the type ASD12-N
with a transmitter that is integrated into the bioreactor basic unit.
Measuring range of absorption: 0 – 6 CU.
The OD parameter is set to this measuring range, too.
There are three different sensors with three different optical path
lengths available:
 OPL01: for very high cell densities
 OPL05: for higher cell densities
 OPL10: for lower cell densities
The ASD12-N sensors supply a non-linearised turbidity measurement
for the culture. This can be linearised manually using the soft
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sensor in eve®, for example, in order to determine correlation with
factors such as the biomass concentration or optical density.
Details on technical data, use and maintenance of the measuring
system can be found in the separate documentation of the sensor
manufacturer.
5.20 Capacitance
Measures the capacity that correlates to the live biomass. This is
measured using an ABER FUTURA biomass sensor. The measurement
range is 0 pF cm-1 to 400 pF cm-1.
Sensors of the ABER Futura systems measure the permittivity
(also: capacitance) and conductivity of the culture. This measured
data can be used to determine a correlation with the live biomass
concentration, for example, using the soft sensor in eve® or data
evaluation.
The sensor with the corresponding transmitters must be purchased
directly from the manufacturer ABER. INFORS HT offers a connection
to the transmitter on the basic unit.
All information about the ABER Futura system is available in the
separate documentation provided by the manufacturer.
5.21 Conductivity
If the bioreactor is equipped with an ABER FUTURA biomass sensor,
this can also be used to measure conductivity.
In this case the measuring range is: 0 - 40 mS cm-1
Sensors of the ABER Futura systems measure the permittivity
(also: capacitance) and conductivity of the culture. This measured
data can be used to determine a correlation with the live biomass
concentration, for example, using the soft sensor in eve® or data
evaluation.
The sensor with the corresponding transmitters must be purchased
directly from the manufacturer ABER. INFORS HT offers a connection
to the transmitter on the basic unit.
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All information about the ABER Futura system is available in the
separate documentation provided by the manufacturer.
5.22 Redox
Measures the reduction/oxidation potential (redox) in the medium.
Two systems are available for redox measurement:
Analogue system
 Measuring range: –2000 mV bis +2000 mV.
 Classic combined sensor (oxidation reduction potential measurement
against a reference)
 Manufacturer: METTLER TOLEDO
To use the sensor, the basic unit must be equipped with a corresponding
connection.
Digital system
 Measuring range: -1500 mV bis +1500 mV.
 Classic combined sensor (oxidation reduction potential measurement
against a reference) with integrated electronics, type
Easyferm Plus ORP ARC.
 Manufacturer: HAMILTON
If the basic unit is configured for Hamilton sensors, the redox sensor
can be connected instead of the pO2 sensor. If the sensor is
configured in addition to the Hamilton pO2 sensor or if the basic
unit is configured for Mettler sensors, an additional connecting cable
is required.
The redox sensor is usually not calibrated/adjusted. However, the
calibration of the sensor can be checked using the appropriate redox
buffer solution.
 METTLER system: 1-point calibration in the calibration menu
of the redox parameter in the touch screen software from the
administrator user level.
 HAMILTON system: Calibration using a Hamilton Arc
Handheld or a Hamilton Arc USB cable, both of which are
available separately from the sensor manufacturer.
Details on technical data, use and maintenance of the Redox sensors
can be found in the separate documentation of the sensor
manufacturers.
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5.23 pCO2
Measures the saturation of dissolved carbon dioxide (CO2) in the
culture in hPa.
 Measuring range: 0 - 1000 hPa
 Digital CO2 sensor with integrated temperature sensor, type
InPro5000i ISM
 Manufacturer: METTLER TOLEDO (sensor and transmitter)
The measurement display of the pCO2 parameter in the touch
screen software is set similarly to the measurement display of the
transmitter.
If a CO2 gas line is available with a mass flow controller (CO2 Flow
parameter), this can be used to control the pCO2.
The sensor is calibrated directly at the transmitter according the
manufacturer’s specifications.
Details on technical data, use and maintenance of the pCO2 sensor
and the associated transmitter can be found in the separate
documentation of the manufacturer METTLER TOLEDO.
5.24 JTemp
Labfors 5 BioEthanol
As a result of the high solid content inside the vessel, the heat
transfer from the vessel jacket to the culture vessel is not ideal,
which means that there can be a high temperature drop from the
jacket to the vessel content. In some circumstances this may lead
to inactivating enzymes/bacteria close to the jacket. It can therefore
be useful to limit the maximum temperature of the vessel
jacket.
To do this you need to create a cascade for the parameter Temp
(temperature), whereby the JTemp is specified as a control parameter.
Within the limits of the minimum and maximum setpoint, the
jacket temperature of the system varies to reach the required setpoint
for the Temp parameter.
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6 Parameter Options
Parameter options are setting menus for the parameters. They are
shown as tab pages in the Properties dialogue box for the selected
parameter. The figure above shows the example of the Temp properties
dialogue box (temperature parameter).
The parameters and their options (setting menus) for each individual
bioreactor are called up in main menu Controller.
Depending on the access authorisation and the type of the parameter,
more or less options may be available.
For details on user levels and their access authorisations see the
chapter “Access Authorisation of User Groups”.
Every properties dialogue box for each parameter has two buttons:
 OK: Saves inputs, closes dialogue box
 Cancel: Closes the dialogue box without changes
Most parameters have the following options:
 Setpoint: This is where setpoint values, alarm values and critical
values can be set and where parameters can be switched
on and off.
 Calibrate: This is where the sensors’ measured values are cal-
ibrated.
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This option is only available for calibration of the measured
values of the pH, pO2 and OD sensors (OPTEK system) on
user levels User and Technician. All other calibration menus
are only accessible on user level Administrator and above.
 PID: This is where controller settings are made.
 Options: This is where the basic parameter settings are made.
This option is only accessible to the manufacturer’s qualified
personnel. This option is not visible or enabled at any other
user level.
The following chapters describe the content and function of the individual
tab pages, i.e. parameter menus. Each menu description
is followed by either detailed setting instructions or a cross reference
to the respective corresponding in these operating instruc-
tions.
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6.1 Setpoint
The tab page for the Setpoint option is divided up into a three-column
main area with input fields and view boxes and a Controller
area.
Columns
 Property: designation of the input fields and view boxes
 Value: values of the input fields and view boxes
 Bar: graphic display of the values as in main menu Controller.
For details refer to chapter “Main Menus”, “Controller – Value
Display”.
Input fields and view boxes
 Setpoint: to enter the setpoint
 Value: displays the current value
 Output: Shows the controller output as a percentage.
 Lower Critical: to enter the lower critical value
 Lower Alarm: to enter the lower alarm value
 Upper Alarm: to enter the upper alarm value
 Upper Critical: to enter the upper critical value
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Controller
 Auto: to switch on the parameter into automatic mode. In this
mode, it is possible to switch the parameter on or off by touching
the controller output (displayed value OFF or %) in main
menu Controller during a running fermentation/cultivation.
 OFF: to switch off the parameter. This mode deactivates the
controller output in main menu Controller, too.
The pH parameter has the additional function pH temperature
comp. (pH temperature compensation). It has to be switched on
during a fermentation/cultivation process so that temperature-compensated
values can be generated. That means, the temperature
dependency of the measuring principle will be corrected.
pH of liquids is temperature-dependent, too. Therefore pH will still
be responsive to temperature variation, although temperature compensation
is switched on.
This function also has to be switched on to calibrate the pH sensor
whilst simultaneously measuring the temperature of the pH buffer
solution or manually entering the temperature of the buffer solution.
INFORMATION
Temperature compensation is only relevant when the analogue
measuring system is configured for the use of pH sensors from
the manufacturer METTLER. The digital measuring system which
uses pH sensors from the manufacturer HAMILTON this function
is integrated into the sensor, and is therefore not used in the
touch screen software.
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6.1.1 Setting Setpoint Values, Switching Parameters ON / OFF
Parameter setpoint values are basically set in the start dialogue for
one bioreactor or all bioreactors. Once the bioreactor(s) is/are running,
setpoint values can be changed then via main menu Controller
for each bioreactor individually.
Parameters can be switched on or off in the start dialogue or via
main menu Controller once the bioreactor(s) is/are running, if their
controller output is set to automatic mode in the Setpoint option of
the parameter.
In stopped state of a bioreactor, all its parameters are automatically
switched off and cannot be switched on.
INFORMATION
Bioreactor(s) is/are always started with the settings in the start dialogue.
Changes to these settings are saved and transferred to
the next start dialogue. If setpoint values are changed or parameters
are switched on/off whilst a bioreactor is running, these settings
are only adopted for the current fermentation process.
Note the following when setting setpoints:
When using a lightly foaming medium, set the setpoints in parameters
Stirrer (stirrer speed) and the different Flow parameter(s) as
low as possible if this does not have a negative effect on the oxygen
supply to the culture.
If there is still heavy foaming, a chemical antifoaming agent will
need to be used. In this case the Dose time and Wait time in the
parameter Antifoam has to be set accordingly.
Settings in the start dialogue
To make the setings in the start dialogue, proceed as follows:
Procedure 1. Select the desired bioreactor from the selection bar, e.g. bioreactor
A.
2. Call up main menu Batch and press Start.
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The Start bioreactor A operation (start dialogue) dialogue box
appears with:
 Parameter: lists all the available (depending on the
equipment configuration) parameters
 Output Active: to switch each parameter individually on
or off, if the Controller in the Setpoint option of the parameter
is set to automatic (Auto) mode.
 Setpoint: lists all parameter setpoint values with which
the bioreactor is started. Setpoint values can be
changed here.
 OK: to save inputs and start the bioreactor (fermenta-
tion/cultivation)
 Cancel: to close the dialogue box without changes
3. Press Setpoint of the desired parameter, e.g. Stirrer.
The numeric keypad appears.
4. Type in the desired setpoint value, e.g. 300, and confirm with
the OK key.
The numeric keypad disappears; the value is accepted for the
Setpoint view box/input field.
5. Repeat the same procedure for all desired parameters.
6. Switch on/off parameters as required.
7. Press OK.
The dialogue box disappears, the settings are saved, the bioreactor
(fermentation/cultivation) is started.
When all bioreactors are selected (ALL), they are all started
with the same settings.
Changed settings are transferred to the next start dialogue.
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Settings on a running bioreactor
To make the settings on a running bioreactor the following two options
are available:
a) Directly via the Setpoint input field/view boxes and the controller
output buttons in the Output column of the main menu
Controller.
b) In the Setpoint menu of the selected parameter in the Parameter
column of the main menu Controller.
INFORMATION
Changed settings are adopted for the fermentation/cultivation process
in progress only.
Proceed as follows:
Variant a)
Procedure 1. Select the desired bioreactor from the selection bar, e.g. bioreactor
A.
2. Call up main menu Controller.
3. Press the Setpoint input field/view box of the desired parameter,
e.g. Temp.
The numeric keypad appears.
4. Type in the desired setpoint value, e.g. 38, and confirm with
the OK key.
The numeric keypad disappears; the value is accepted for the
Setpoint view box/input field.
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5. Press the controller output button of the parameter.
The parameter is switched on, the controller output changes
from OFF to the display of the corresponding numeric value in
%.
INFORMATION
To switch the parameter i.e. controller output on or off here, is
only possible, if the controller of the parameter is set to automatic
(Auto) mode in its Setpoint option. See also next procedure in
variant b).
6. Repeat the same procedure for all desired parameters.
Variant b)
Procedure 1. Select the desired bioreactor from the selection bar, e.g. bioreactor
A.
2. Call up main menu Controller.
3. Press the desired parameter button, e.g. Temp, in the Parameter
column.
Temp properties menu appears with option Setpoint automatically
selected.
4. Press Setpoint.
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The numeric keypad appears.
Type in the desired setpoint value, e.g.38, an confirm with the
OK key.
The numeric keypad disappears; the value is accepted for the
Setpoint input field.
5. Change alarm values and critical values as required.
INFORMATION
For details about alarm value and critical value settings refer to
chapter „Setting Alarm Values and Critical Values”.
6. Ensure the controller output is switched to automatic mode
(Auto), change setting as necessary.
The parameter is set switched on now.
7. Press OK.
The dialogue box disappears, the settings are saved.
8. Repeat the same procedure for all desired parameters.
Invalid setpoint value or alarm limit input
When an invalid setpoint, alarm or critical alarm value is entered, a
corresponding Invalid input dialogue box appears after confirming
the entered value via OK key.
Example with input of setpoint > max. value
Invalid input dialogue box appears with:
 Setpoint should be <= max. value
 OK: To close the dialogue box without changes and enter a
new setpoint.
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Example with input of upper critical value > max. value
Invalid input dialogue box appears with:
 Your alarm limits are not ordered correctly. Upper critical
should be <= max. value.
 OK: To close the dialogue box without changes and enter a
new value.
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6.2 Calibrate
The tab page for the Calibrate option contains four view boxes and
a button:
 Reading: shows the current measured value in digital units
 Value: shows the current measured value depending on the
last calibration
 Slope: shows the digital value of the calculated slope of the
calibration line
 Offset: describes the intersection point of the calibration line
with the X axis
 Calibrate: To open the calibration menu
The Reading, Slope and Offset view boxes are not relevant for the
digital measuring system with HAMILTON pH and pO2 sensors.
These values are memorised directly in the sensor’s integrated
electronics. Calibration menus for METTLER and HAMILTON pH
and pO2 sensors differ from each other and are described in detail
in the following chapters.
INFORMATION
The calibration menus for pH and pO2 can also be called up directly
via Calibrate pH and Calibrate pO2 in the main menu
Batch.
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6.2.1 Calibration Menus METTLER Sensors
The below figures show the calibration menu for METTLER pH
sensors on the left-hand side and on the right, the calibration menu
for METTLER pO2 sensors. Both menus look essentially the same,
small differences are explained in the following menu description.
The calibration menu contains the following:
Header: Calibration mode
 2 point: To select 2-point calibration mode.
This mode is automatically selected in the calibration menu for
pH sensor calibration.
 1 point: To select 1-point calibration mode.
If you need to recalibrate the pH sensor, this is carried out in
1-point calibration mode.
 Manual: To select manual calibration mode
This mode is only relevant to the user for parameter pH. The
menu contains:
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 Slope: To manually change the slope
 Offset: To manually correct the offset (= the same effect as
recalibration in 1-point mode).
For details on recalibration see the chapter “Recalibrating a
METTLER pH Sensor”.
INFORMATION
For all other parameters the manual button is only relevant to the
manufacturer's service specialists. The necessary full menu can
only be accessed at the service level.
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Main section: Line 1 and 3
 Instruction: Please set value of the first / of the second calibration
point.
 Use As Setpoint (pO2): this function is only relevant and can
only be used under certain circumstances at the Technician
user level. For details see the chapter “Special function USE
AS SETPOINT”.
INFORMATION
For all other parameters the USE AS SETPOINT button is only
relevant to the manufacturer’s service specialists.
Main section: Line 2 and 4
 Instruction: Put sensor into media and confirm measure. For
the pH sensor this is the buffer solution.
 Sensor data: Displays the measurement
 Confirm Measure: To confirm measurement
INFORMATION
The input fields and buttons in line 3 and 4 are only available
once the first measurement has been confirmed. Line 3 and 4 are
faded out in 1-point calibration mode.
Lower section
 Sensor quality display bar: Charts the quality of the sensor.
If the green colour in the display bar is barely or not at all visi-
ble:
 pH sensor: Replace the sensor.
 pO2 sensor: Replace the membrane body of the sensor in
accordance with the sensor manufacturer's instructions in
separate documentation.
If the green colour fills less than half of the display bar:
 pO2 sensor, recommended: replace the sensor in accordance
with the sensor manufacturer's instructions in separate
documentation.
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 Ref. Temp: Displays the measured temperature of the reference
buffer solution, or is used as an input field to manually
enter the temperature of the reference buffer solution.
INFORMATION
This field is only relevant for the pH sensor. It is only visible and
available if the temperature compensation function in the setpoint
menu has been switched on.
Footer
 Restart calibration: To restart the calibration.
 Cancel calibration: To abort calibration.
 OK: To confirm calibration, close calibration menu
OK and Restart are only available once at least one measurement
has been confirmed.
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6.2.2 Calibration Menu HAMILTON Sensors
The below figures show the calibration menu for HAMILTON pH
sensors on the left-hand side and on the right, the calibration menu
for HAMILTON pO2 sensors. The two menus look similar, small
differences are explained in the following menu description.
The calibration menu contains the following:
Header Calibration Mode/both calibration menus
 1 point: To select 1-point calibration mode.
 pH: this button does not exist because it is generally a
2-point calibration being performed.
 2 point: To select 2-point calibration mode
INFORMATION
A 2-point calibration with HAMILTON pO2 sensors is generally
also possible in succession in 1-point calibration mode.
 Product: To select product calibration mode for pH sensor.
This function is not relevant for the pO2 sensor.
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Main section, pH sensor calibration menu
Line 1 and 3
 Instruction: Put the probe into the first / second buffer and select
its value.
Hold the sensor into the first respectively the second buffer
solution and select the value in the drop-down menu.
INFORMATION
The pH sensors are pre-calibrated at the factory using the two following
standards: pH 4 (calibration point 1), and pH 7 (calibration
point 2) at room temperature. The following buffers within Hamilton
standards set are defined as factory default for calibration
with automatic buffer recognition (Auto in drop-down menu): pH
4.01, pH 7.00 and pH 10.01.
Line 2 and 4
 Instruction: Press the "Calibrate Point 1 / Point 2" button to
start calibration.
 Sensor data: Displays the measurement
 Calibrate Point 1 / 2: To calibrate the first or second point.
Main section, pO2 sensor calibration menu
Line 1
 Instruction: Put the sensor into the standard buffer. The
buffer’s value must be 0%-sat or in range (xx.xxx%-
sat...yyy.yyy%).
Keep the sensor in the standard buffer solution (here the medium
in the culture vessel). The medium either needs to show
0% air saturation or be within a range from xx.xxx %sat...yyy.yyy
%-sat (the value is read by the sensor).
INFORMATION
The measurement parameter is preconfigured to %-sat in the factory
of the equipment. When performing a 2-point calibration, always
first calibrate the zero point (0 %)!
Line 2 (and 4 if 2-point calibration mode is selected)
 Instruction: Set the buffer’s value and press the “Calibrate
Point” button.
 Buffer’s value: set the calibration point value
 Calibrate Point: To start calibration.
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Lower section calibration menu
This section displays dates and values that are given by the sensor
manufacturer's firmware that is integrated in the sensor.
pH sensor
 Offset and Slope: shows the calculated values for the Offset in
mV and for Slope in mV/pH
 Ref Temp K: shows the reference temperature in Kelvin.
pO2 sensor
 Information Current reading: shows the current measured
value.
Both sensors
 Sensor quality display bar: charts the quality of the sensor in a
scale from 0 to 100 %
 Sensor Information: To call up sensor information of the sensor
manufacturer.
 Sensor type Hamilton: shows the connected sensor type,
Hamilton
 Operating Hours:…: shows how long the sensor has been op-
erating.
Footer
 OK: To exit the calibration menu.
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6.2.3 pH Sensor Calibration
The bioreactor is configured at the factory with a measurement
system either for analogue classic pH sensors from the manufacturer
METTLER or for digital pH sensors, type Easyferm Plus ARC,
from the manufacturer HAMILTON.
For all pH sensors it generally applies that a reliable pH measurement
always needs a 2-point calibration with a high and low reference
buffer. It also applies that the calibration should be performed
again before each fermentation/cultivation process. Calibration
must be performed prior to sterilisation, in other words before
mounting the pH sensor in the vessel.
The sequence that the two reference points are calibrated is irrelevant
for both measurement systems.
Detailed information on the calibration of sensors and of the pH
buffers supported by the sensors can be found in separate documentation
provided by the sensor manufacturer.
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6.2.3.1 Calibrating a METTLER pH Sensor
The correct temperature of the buffer solution must be measured to
achieve extremely exact calibration results. This can be measured
directly using the temperature sensor of the equipment during calibration.
Another option is to measure the temperature externally
and enter the value manually using the operating panel. If not
measured or manually input, the buffer temperature is assumed to
be 20 °C.
The following describes a 2-point calibration of a METTLER pH
sensor with simultaneous temperature measurement of the buffer
solution. This means that the calibration takes place with temperature
compensation switched on. This corrects the temperature dependence
of the measurement principle.
The pH of liquids is also temperature dependent, which is why the
pH also reacts to temperature deviations when temperature compensation
is switched on.
Information on technical data, use, maintenance and servicing can
be found in the separate sensor documentation of the manufac-
turer.
For the calibration proceed as follows:
Procedure 1. Connect the sensor cable.
Ensure the cable is not buckled or twisted.
ATTENTION
The integrity of the sensor cable can be damaged by buckling or
twisting. This may lead to faulty measurements.
2. Select the desired bioreactor from the selection bar in the
touch screen software. This means the bioreactor to which the
pH sensor is attached.
3. Call up main menu Controller, select parameter pH and call up
Option Setpoint.
4. Switch pH temperature compensation on.
5. Press OK.
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The dialogue box disappears, the setting is stored.
6. Carefully remove the watering cap from the pH sensor and
rinse the pH sensor with distilled water, do not rub!
ATTENTION
Dry wiping or rubbing a pH sensor after rinsing can cause electrostatic
charge. This can greatly increase the response time and
generate incorrect measurements. At most, gently dab a pH sensor
after rinsing, NEVER rub or wipe it!
7. Call up main menu Batch and press Calibrate pH.
The calibration menu Calibrate pH probe appears.
The 2-point calibration mode is automatically selected. The
Ref. Temp input field/view box is displayed.
INFORMATION
Without switching pH temperature compensation on before, this
field is not visible.
8. Press the input field in line 1.
The numeric keypad appears.
9. Type in the value of the low (or high) reference buffer confirm
with the OK key.
INFORMATION
The order in which the reference points are calibrated is irrele-
vant.
The numeric keypad disappears, the value is adopted.
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10. Put the pH sensor with the temperature sensor (Pt100) into
the relevant buffer solution.
The measurement (in mV) is displayed in line 2 in Sensor
data.
As soon as the measurement is stable:
11. Press Confirm Measure in line 2.
The calibration value is accepted. The input fields and buttons
in line 3 and 4 are available now.
NOTICE!
The signal characteristics are asymmetric. In other words, the
closer the signal comes to the real value, the slower the change.
The calibration is inaccurate, if the measurement is confirmed
with OK before the sensor signal has completely stabilised. Wait
a few minutes before confirming with OK and check the reading
again, if in doubt.
12. Rinse the pH sensor with distilled water, do not rub!
13. Press the input field in line 3.
The numeric keypad appears.
14. Type in the value of the high (or low) reference buffer and
confirm with the OK key.
INFORMATION
The order in which the reference points are calibrated is irrele-
vant.
The numeric keypad disappears; the value is adopted.
15. Put the pH sensor with the temperature sensor (Pt100) into
the relevant buffer solution.
The measurement (in mV) is displayed in line 4 in Sensor
data.
As soon as the measurement is stable:
16. Press Confirm Measure in line 4.
The calibration value is accepted.
17. Press OK.
The dialogue box disappears, the calibration values are
stored.
18. Rinse the pH sensor with distilled water, do not rub!
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19. Release the sensor cable from the pH sensor, if necessary,
reattach the watering cap.
20. Continue with the preparatory work for sterilisation.
6.2.3.2 Recalibrating a METTLER pH Sensor
To compensate for a deviation (drift) in the measurement over a
long-term fermentation, it is possible and sufficient to recalibrate
with a 1-point calibration. This means that the pH of a sample
measured using an external measurement device is accepted as
the new reference value in 1-point calibration mode.
The same effect is achieved by manually correcting the offset (deviation).
In other words, the difference between the externally determined
measurement and the displayed measurement in the culture
needs to be added to or subtracted from the last calculated
offset value depending on the result. The correction is made in
manual calibration mode. The menu is illustrated in chapter “Calibration
Menus METTLER Sensors”.
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6.2.3.3 Calibrating a HAMILTON pH Sensor
The pHs and the temperature dependency of pH buffers are stored
in the HAMILTON pH sensors and are automatically detected on
calibration. It is therefore not necessary to measure the temperature
of the used buffer solution separately.
The following describes a 2-point calibration of a HAMILTON pH
sensor. Which reference point in the 2-point calibration is calibrated
first is irrelevant for this type of sensor.
Information on technical data, use, maintenance and servicing can
be found in the separate sensor documentation of the manufac-
turer.
Proceed as follows:
Procedure 1. Connect the sensor cable.
Ensure the cable is not buckled or twisted.
2. Carefully remove the cap with the storage solution from the
pH sensor and rinse the sensor with distilled water, do not rub
it!
ATTENTION
Dry wiping or rubbing a pH sensor after rinsing can cause electrostatic
charge which can greatly increase response time and generate
incorrect measurements. At most, gently dab a pH sensor
after rinsing, NEVER rub or wipe it!
3. In the touch screen software, select the required bioreactor
from the selection bar. In other words, the bioreactor to which
the pH sensor is connected.
4. Call up the Controller main menu und check pH:
Communication is established, if a pH value of ≠ -1.0 is dis-
played.
5. Call up main menu Batch and press Calibrate pH.
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The calibration menu Calibrate Hamilton pH appears.
The 2 point calibration mode is automatically selected.
6. Place the pH sensor in the buffer solution of the first reference
point, e.g. a solution of pH 4.01.
7. On line 1, in the drop-down menu, either leave the Auto entry
of the possible pH reference values or select the appropriate
value.
INFORMATION
The pH sensors are pre-calibrated at the factory using the two following
standards: pH 4 (calibration point 1), and pH 7 (calibration
point 2) at room temperature. The following buffers within Hamilton
standards set are defined as factory default for calibration
with automatic buffer recognition (Auto in drop-down menu): pH
4.01, pH 7.00 and pH 10.01.
The measured value is displayed in line 2 in Sensor Data.
As soon as the measured value is stable:
8. Press Calibrate Point 1.
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The dialogue box Hamilton pH sensor calibration appears
with:
 Display bar: charts the course of the calibration. The
progress is shown by a green colour.
 Precise calibration takes 3 minutes
 Time left: x:xx: shows the lime left in minutes and sec-
onds.
 Cancel calibration: to abort calibration.
9. Wait until calibration is complete.
As soon as calibration has successfully completed:
 Display bar: entirely filled
 Successfully calibrated at …: shows that the calibration
is completed with the selected reference value
 OK: to close the dialogue box.
10. Press OK.
The calibration is confirmed, the dialogue box disappears.
11. Rinse the pH sensor with distilled water; do not rub!
12. Place the pH sensor in the buffer solution of the second reference
point, e.g. a solution of pH 7.00.
13. On line 3, in the drop-down menu, either leave the Auto entry
of the possible pH reference values or select the appropriate
value
The measured value is displayed in line 4 in Sensor Data.
As soon as the measured value is stable:
14. Press Calibrate Point 2.
The dialogue box Calibrate Hamilton sensor appears again,
charting the course of calibration.
15. Wait until calibration is complete
16. Press OK.
Calibration is confirmed; the dialogue box disappears.
17. In the calibration menu, press OK to close the menu.
18. Rinse the pH sensor with distilled water; do not rub!
19. Release the sensor cable from the pH sensor; if necessary,
reattach the storage cap.
20. Continue with the preparatory work for sterilisation.
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6.2.3.4 HAMILTON pH Sensor Product Calibration
Adapting the calibration curve to the current process conditions is
possible by performing a product calibration.
Further information on product calibration can be found in the separate
documentation of the HAMILTON sensor manufacturer.
To perform a product calibration, proceed as follows:
Procedure 1. Call up the calibration menu of the pH sensor.
2. Press Product to initialise product calibration.
3. Take a sample from the process (in the culture vessel) and
perform a laboratory measurement of the sample at the same
temperature as the measurement was taken in the process.
4. Press Take Sample in line 1 (Take a sample of the product
media for analysis).
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The message Sample taken appears on the left of the button.
5. Touch the input field in line 2.
The numeric keypad appears.
6. Type in the externally measured pH (e.g. 7.2) confirm with the
OK key.
7. Press Calibrate in line 2.
The dialogue box Hamilton pH sensor calibration appears, calibration
begins. The progress is illustrated in green in the display
bar.
INFORMATION
Product calibration can only be performed and be effective if the
externally measured and input pH does not deviate by more than
2 pH units from the original pH.
As soon as calibration has successfully completed, the dialogue
box contains:
 Display bar entirely filled
 Message: Display Successfully calibrated at …: Shows that
the calibration is completed with the input pH value
 OK: To close the dialogue box
8. Press OK.
Calibration is completed; dialogue box disappears.
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In the calibration menu, the Calibrate button is no longer
available. The message Product calibration active appears.
9. Press OK to close the menu.
INFORMATION
To restore the original calibration curve, the product calibration
can be overruled at any time. This is easy to do by calling up the
calibration menu again and touching the 2 points button. A new
standard calibration (2-point calibration) overrules the product cal-
ibration.
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6.2.4 Calibrating all pH Sensors
The Calibrate ALL pH function is available as soon as more than
one bioreactor = culture vessel is controlled using the touch screen
software. A maximum of 6 bioreactors can be controlled using an
operating panel with the touch screen software.
For the bench-top bioreactors Labfors 5 and Multifors 2 this
means:
Labfors 5
1 unit = 1 bioreactor = 1 culture vessel
(max. 1 master unit with 5 satellite units is possible)
Multifors 2
1 unit = 2 bioreactors = 2 culture vessels
(max. 1 master unit with 2 satellite units is possible)
The function enables you to perform a 2-point calibration for multiple
or all connected METTLER pH sensors at the same time.
It is possible to handle the pH sensors and buffer solutions in various
ways.
For example:
a) Place all pH sensors in a container with the buffer solution at
the same time and calibrate the first and the second point one
after the other.
b) Place each pH sensor in the buffer solution individually (or in
pairs for Multifors 2) and calibrate the first point of each pH
sensor one after the other. Repeat the same process for the
second point.
c) Place all pH sensors in a container with the buffer solution individually
and calibrate the first and the second point one after
the other.
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6.2.4.1 Calibrating all METTLER pH Sensors
For METTLER pH sensors, the temperature of the buffer solution
must be determined externally, it cannot be measured using the
temperature sensor in this case. If no temperature is manually input
for the buffer solution, a buffer temperature of 20 °C is as-
sumed.
The following example describes a 2-point calibration in which the
exact temperature of the buffer solutions is entered and the maximum
possible number of connected pH sensors (6 sensors) is
used.
The method a) is applied as described in the general chapter “Calibrating
all pH Sensors – General Information”.
Proceed as follows:
Procedure 1. Prepare two containers, e.g. graduated beakers, with the two
buffer solutions with known temperatures.
2. Connect all pH sensors in turn to their sensor cable.
Ensure the cables are not buckled or twisted.
ATTENTION
The integrity of the sensor cables can be damaged by buckling or
twisting. This may lead to faulty measurements.
3. Select all (All) bioreactors from the selection bar.
4. Call up the Batch main menu and press Calibrate All pH.
The calibration menu Calibrate pH probes appears with:
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Line 1 and 3:
 Instruction: Place the probes into first/second buffer enter
their reference value.
 Instruction: Enter Reference Value
Additionally on line 1
 Reference Temp °C: To activate the function for manual
entry of the temperature of the buffer solution in °C and
to enter the value itself.
Line 2 and 4:
 Instruction: Press Bior button once the sensor data is
stable
 Current Sensor Data: Displays current measurements in
mV
 Press to confirm calibration and Bior A to Bior F: To
confirm each pH sensor measurement by pressing the
relevant button.
The input fields and buttons in line 3 and 4 are only available
once the first measurements have been confirmed.
Footer
 Restart calibration: To restart calibration
 Cancel: To cancel calibration
 OK: To confirm calibration and close the calibration
menu.
5. Activate the reference temperature function.
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The input field is available now.
6. Press Reference Temp.
The numeric keypad appears.
7. Type in the temperature of the buffer solution, e.g. 23 (°C),
and confirm with the OK key.
The numeric keypad disappears.
The value is adopted.
8. Remove the watering cap of each pH sensor in turn and rinse
the pH sensor with distilled water, do not rub!
ATTENTION
Dry wiping or rubbing a pH sensor after rinsing can cause electrostatic
charge. This can greatly increase the response time and
generate incorrect measurements. Gently dab a pH sensor after
rinsing, NEVER rub or wipe it!
9. Press Reference value in line 1.
The numeric keypad appears.
10. Type in the value of the low (or high) reference buffer and
confirm with the OK key.
The order in which the reference points are calibrated is irrele-
vant.
The numeric keypad disappears; the value is adopted.
11. Place all pH sensors in the relevant buffer solution.
Measurements (in mV) of each pH sensor are displayed in
line 2 in Current Sensor Data above the BiorA to BiorF but-
tons.
Once all measurements are stable:
12. Press button BiorA to BiorF one after another.
The calibration values are accepted. The input fields and buttons
in line 3 and 4 are now available.
INFORMATION
The signal characteristics are asymmetric. In other words, the
closer the signal comes to the real value, the slower the change.
The calibration is not accurate, if the measurement is confirmed
with OK before the sensor signal is completely steady. Wait a few
minutes before confirming with OK and check the reading again,
if in doubt.
13. Rinse all pH sensors with distilled water, do not rub!
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14. Press Reference value in line 3.
The numeric keypad appears.
15. Type in the value of the high (or low) reference buffer and
confirm with the OK key.
The order in which the reference points are calibrated is irrele-
vant.
The numeric keypad disappears; the value is adopted.
16. Place all pH sensors in the relevant buffer solution.
Measurements (in mV) of each pH sensor are displayed in line
4 in Current Sensor Data above the BiorA to BiorF buttons.
Once all measurements are stable:
17. Press button BiorA to BiorF one after another.
The calibration values are accepted.
18. Press OK.
The menu disappears, the calibration values are stored.
19. Rinse all pH sensors with distilled water, do not rub!
INFORMATION
To be able to assign the sensors to the relevant bioreactor again
after calibration, identify these accordingly if necessary, for example,
using lab tape or something similar.
20. Release the sensor cables from the pH sensors, if necessary,
reattach the watering caps.
21. Continue with the preparatory work for sterilisation.
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6.2.4.2 Calibrating all HAMILTON pH Sensors
The pHs and the temperature dependency of pH buffers are stored
in the HAMILTON pH sensors and are automatically detected on
calibration. It is therefore not necessary to measure the temperature
of the used buffer solution separately.
The following example describes a 2-point calibration of two pH
sensors (Bior A and Bior C).
The method a) is applied as described in the general chapter “Calibrating
all pH Sensors”, method example a).
Proceed as follows:
Procedure 1. Prepare two containers, e.g. graduated beakers, with the two
buffer solutions with known temperatures.
2. Connect the pH sensors in turn to their sensor cable.
Ensure the cables are not buckled or twisted.
3. Select all (All) bioreactors from the selection bar.
4. Call up the main menu Batch and press Calibrate All pH.
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The calibration menu Calibrate pH probes appears with:
Line 1+3: Place the probes into first / second buffer and
enter their reference value
 Enter Reference Value: to enter, respectively select the
reference value.
Line 2+4: Press Bior button to calibrate sensor
 Bior A to Bior F: to start calibration of each pH sensor
by pressing its appropriate bioreactor button.
Footer
 Current Value: shows the current measured value
 Sensor Quality: charts the quality of the sensor in a
scale from 0 to 100 % in form of a display bar.
 Calibration Status: displays the calibration status
 OK: to exit the calibration menu.
5. Remove the cap with the storage solution from each pH sensor
in turn and rinse the pH sensor with distilled water!
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ATTENTION
Dry wiping or rubbing a pH sensor after rinsing can cause electrostatic
charge which can greatly increase response time and generate
incorrect measurements. At most, gently dab a pH sensor
after rinsing, NEVER rub or wipe it!
6. Place all pH sensors in the buffer solution of the first reference
point, e.g. a solution of pH 4.01.
7. Either leave the Auto entry in the drop-down menu of the possible
pH reference values or select the appropriate value in
the menu.
INFORMATION
The pH sensors are pre-calibrated at the factory using the two following
standards: pH 4 (calibration point 1), and pH 7 (calibration
point 2) at room temperature. The following buffers within Hamilton
standards set are defined as factory default for calibration
with automatic buffer recognition (Auto in drop-down menu): pH
4.01, pH 7.00 and pH 10.01.
Measurement of each pH sensor is displayed.
8. Press the bioreactor buttons one after another, in this case
BiorA and BiorC.
Progress bars of the calibration procedure appear instead of
the different buttons.
9. Wait until calibration is complete.
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Successful calibration is shown with OK in the Calibration Status
line. In case of appearance of a number instead of OK:
this indicates an error which is a direct output of the sensors’s
integrated software from the sensor manufacturer HAMILTON.
INFORMATION
A list with error codes and their description can be found in chapter
“Error Codes HAMILTON pH Sensor Calibration”.
10. Rinse each pH sensor with distilled water, do not rub!
11. Place all pH sensors in the buffer solution of the second reference
point, e.g. a solution of pH 7.00.
12. Either leave the Auto entry in the drop-down menu of the possible
pH reference values or select the appropriate value in
the menu.
Measurement of each pH sensor is displayed.
13. Press BiorA and BiorC one after another.
The progress bars of the calibration procedure reappear again
instead of the different buttons.
14. Wait until calibration is complete.
After successful completion of the calibration (Calibration Status
= OK):
15. In the calibration menu, press OK to close the menu.
16. Rinse each pH sensor with distilled water, do not rub!
17. Release the sensor cables from each pH sensor, if necessary,
reattach the storage caps.
INFORMATION
To be able to assign the sensors to the relevant bioreactor again
after calibration, identify these accordingly if necessary, for example,
using lab tape or something similar.
18. Continue with the preparatory work for sterilisation.
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6.2.4.3 Error Codes Calibrating all HAMILTON pH Sensors
Error Code Description
01 Difference between CP1 (calibration point 1) and CP2 (calibration point 2) < pH 1.0
02 No matching calibration standard
04 Actual temperature reading is too high
08 Actual temperature reading is too low
10 Temperature reading during calibration is not stable
20 Offset at pH 7 is too low or slope is too low
40 Offset at pH 7 is too high or slope is too high
80 pH reading during calibration is not stable
03 01 + 02
= Difference between CP1 (calibration point 1) and CP2 (calibration point 2) < pH 1.0
+ No matching calibration standard
05 01 + 04
= Difference between CP1 (calibration point 1) and CP2 (calibration point 2) < pH 1.0
+ Actual temperature reading is too high
09 01 + 08
= Difference between CP1 (calibration point 1) and CP2 (calibration point 2) < pH 1.0
+ Actual temperature reading is too low
21 01 + 20
= Difference between CP1 (calibration point 1) and CP2 (calibration point 2) < pH 1.0
+ Offset at pH 7 is too low or slope is too low
41 01 + 40
= Difference between CP1 (calibration point 1) and CP2 (calibration point 2) < pH 1.0
+ Offset at pH 7 is too high or slope is too high
90 10 + 80
= Temperature reading during calibration is not stable
+ pH reading during calibration is not stable
INFORMATION
For detailed information about error codes contact the sensor
manufacturer HAMILTON.
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6.2.5 pO2 Sensor Calibration
The bioreactor is configured at the factory with a measurement
system either for analogue polarographic pO2 sensors from the
manufacturer METTLER or for digital optical pO2 sensors, type
Visiferm DO ARC, from the manufacturer HAMILTON
METTLER pO2 sensors are polarographic and therefore need to be
polarised before calibration.
HAMILTON pO2 sensors are preconfigured by the equipment manufacturer
to the measurement parameter %-sat. Replacement sensors
also need to be configured by the equipment manufacturer
before use!
Detailed information on the calibration, use, maintenance and servicing
can be found in the separate sensor documentation of the
sensor manufacturers.
Generally it applies that: calibrating the pO2 sensor should be performed
after sterilisation because sterilisation can change the gradient
of the pO2 sensor.
A 1-point calibration to 100 % is generally sufficient for an exact
measurement and should be carried out again before each fermen-
tation/cultivation.
The zero point (0 % calibration) should be checked at regular intervals
of about 6 months.
Respect the following point:
When performing a 2-point calibration, the 0 % calibration must
always be performed before the 100 % calibration.
100 % calibration conditions
The 100 % calibration of the pO2 sensor is performed under the
following conditions:
 in the medium
 at the operating temperature
 at the maximum expected stirrer speed
 at the maximum expected gassing rate with air or the oxygencontaining
gas(es) provided for fermentation/ cultivation
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0 % calibration conditions
The operating conditions of the 0 % calibration are the same as the
100 % calibration. One exception is the gassing.
To displace oxygen out of the medium, the medium has to be
gassed before and during the 0 % calibration with nitrogen instead
of with air or the gas(es) used for fermentation/cultivation.
6.2.6 Polarising the pO2 Sensor (METTLER)
Polarographic pO2 sensors must be polarised at initial operation or
after disconnection from the voltage source. Correct calibration is
not possible otherwise. This means that the pO2 sensor must be
polarised before calibration.
For polarisation, the sensor cable must simply be connected to the
pO2 sensor and the equipment must be switched on at the main
switch.
Duration of polarisation (= polarisation time) depends on how long
the pO2 sensor has been disconnected from the voltage source (=
depolarisation time)
As a general rule: if depolarisation time > 30 minutes, the minimum
polarisation time is 360 minutes.
More details about polarisation can be found in the separate documentation
form the manufacturer METTLER TOLEDO.
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6.2.6.1 Calibrating a METTLER pO2 Sensor
The following example describes a 2-point calibration of a (polarographic
analogue) METTLER pO2 sensor. This needs to take place
in the correct sequence. This means that the first calibration point
is 0 % (zero point), the second calibration point is 100 %.
Proceed as follows:
Procedure 1. Connect the gassing line to nitrogen. In doing so, leave the
gas supply turned off.
INFORMATION
Depending on the equipment configuration, there may already be
a nitrogen gas line. In this case you only need to adjust the gas
supply accordingly.
2. Select the desired bioreactor from the selection bar in the
touch screen software. This means the bioreactor to which the
pO2 sensor is attached.
3. In main menu Batch, call up the start menu (Start button).
4. Set the temperature setpoint and switch on the parameter.
5. Set the maximum expected stirrer speed during fermentation
and switch on the parameter.
6. Start the bioreactor.
7. Slowly turn on the nitrogen supply and gas the medium.
8. Wait until the required stirrer speed and operating temperature
are reached and the oxygen is displaced out of the medium.
9. Call up main menu Batch and press Calibrate pO2.
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The calibration menu Calibrate pO2 probe appears.
The 2-point calibration mode is automatically selected.
INFORMATION
The Use As Setpoint button is not relevant for this calibration.
If the value in the first input field is not set to 0 (zero for zero
point = 0 %):
10. Press the first input field (…first calibration point) in line 1.
The numeric keypad appears.
11. Type in the value 0 confirm with the OK key.
The numeric keypad disappears; the value is adopted.
As soon as the measurement (line 2, Sensor data) is stable:
12. Press Confirm Measure in line 2.
The value is accepted as 0 % oxygen.
13. Switch off the nitrogen gassing and switch on normal gassing.
14. Set the maximal expected gassing value during fermenta-
tion/cultivation.
If the value in the second input field is not set to 100 (for
100 %):
15. Press the second input field (…second calibration point) in line
3.
The numeric keypad appears.
16. Type in the value 100 and confirm with the OK key.
The numeric keypad disappears; the value is adopted.
17. Wait until the medium is saturated with oxygen.
As soon as the measurement (line 4, Sensor data) is stable:
18. Press Confirm Measure in line 4.
The value is accepted as 100 % oxygen saturation.
19. Press OK.
The dialogue box disappears, the calibration is stored.
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Special Function USE AS SETPOINT
The special function USE AS SETPOINT is for users of the Technicians
user level and is only relevant in the calibration menu of the
pO2 parameter when using METTLER sensors.
It can only be used if a three-fold gas mixture (air/O2/N2) is installed
and the parameter Gasmix is configured in a cascade for the pO2
regulation.
INFORMATION
For all other parameters the USE AS SETPOINT button is only
relevant to the manufacturer’s service specialists.
How it works
In the calibration menu of the pO2 parameter (METTLER sensors):
a) 0 % calibration
The input 0 (%) in the input field of the first calibration point
and touching the USE AS SETPOINT button causes the
Gasmix parameter to switch to nitrogen for this value.
b) 100 % calibration
(2nd point), before entering the 100 value:
The input 21 (%) in the input field of the second calibration
point and touching the USE AS SETPOINT button causes the
Gasmix parameter to switch to air for this value. The value
can then be changed to 100 (%) in the input field and the calibration
completed.
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6.2.6.2 Calibrating a HAMILTON pO2 Sensor
The following example describes a 2-point calibration of a HAMILTON
pO2 sensor, of the type Visferm DO ARC. This needs to take
place in the correct sequence. Which means that the zero point
(0 %) is calibrated before the 100 % oxygen saturation.
INFORMATION
A 2-point calibration can also be performed in turn in 1-point calibration
mode.
Proceed as follows:
Procedure 1. Connect nitrogen to the gassing line.
In doing so, leave the gas supply turned off.
INFORMATION
Depending on the unit configuration, there may already be a nitrogen
gas line. In this case you only need to adjust the gas supply
accordingly.
2. Select the desired bioreactor from the selection bar in the
touch screen software. This means the bioreactor to which the
pO2 sensor is attached.
3. In main menu Batch, call up the start menu (Start button).
4. Set the temperature setpoint and switch on the parameter.
5. Set the maximum expected stirrer speed during fermentation/cultivation
and switch on the parameter.
6. Start the bioreactor.
7. Slowly turn on the nitrogen supply and gas the medium.
8. Wait until the required stirrer speed and operating temperature
are reached and the oxygen is displaced out of the medium.
INFORMATION
The pO2 sensor needs 10 to 15 minutes to warm up after switching
on. In this phase, it can measure. However, for optimum calibration
wait until after this period. A value of -1.0 indicates an error
in communication.
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9. Call up the Batch main menu and touch the Calibrate pO2
button.
The calibration menu Calibrate pO2 probe appears.
1-point calibration mode is automatically selected.
Once the pO2 measurement is stable:
10. Press 2 Points.
2-point calibration mode is activated.
11. Press the input field Buffer’s value in line 2.
The numeric keypad appears.
12. Type in the value 0 and confirm with the OK key.
13. Press Calibrate Point.
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The Hamilton poO2 sensor calibration dialogue box appears
with:
 Display bar: charts the course of the calibration. The
progress is shown by a green colour.
 Display: Precise calibration takes 3 minutes
 Time left: x:xx: displays the remaining time in minutes
and seconds
 Cancel calibration: To abort calibration.
14. Wait until calibration is complete.
As soon as calibration has successfully completed, the dialogue
box contains:
 Display bar entirely filled
 Display Successfully calibrated at 0 %-sat: shows that
the calibration is completed with the selected reference
value
 OK: To confirm calibration and close dialogue box
15. Press OK.
The calibration is confirmed; the dialogue box disappears.
16. Switch off nitrogen gassing and switch on gassing with air.
17. Set the maximal expected gassing value during fermenta-
tion/cultivation.
18. Wait until the medium is saturated with oxygen.
19. Press the input field Buffer’s value in line 4.
The numeric keypad appears.
20. Type in the value 100 and confirm with the OK key.
The numeric keypad disappears; the value appears in the input
field.
21. Press Calibrate Point.
The dialogue box Calibrate Hamilton pO2 sensor appears
again with the message that accurate calibration takes 3 min-
utes.
22. Wait until calibration is complete.
As with 0 % calibration, successful completion is indicated by
a full green bar and the message Successfully calibrated at
xx %- sat.
23. Press OK.
The dialogue box disappears.
24. Press the OK button in the calibration menu to close the
menu.
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6.2.1 Calibrating all pO2 Sensors
The Calibrate ALL pO2 function is available as soon as more than
one bioreactor = culture vessel is controlled using the touch screen
software. A detailed explanation can be found in the chapter “Calibrating
All pH Sensors”.
The function enables you to perform a calibration for multiple or all
connected pO2 sensors at the same time.
The conditions for calibrating all pO2 sensors remain the same as
for calibrating a single pO2 sensor. These are described in detail in
the corresponding chapters.
6.2.1.1 Calibrating all METTLER pO2 Sensors
In the following example a 100% calibration of all (polarographic
analogue) METTLER pO2 sensors is performed. The 0 % calibration
with nitrogen of all METTLER pO2 sensors is not described in
these instructions. The procedure remains the same as described
in the chapter “Calibrating a METTLER pO2 Sensor”.
Proceed as follows:
Procedure 1. Ensure that all pO2 sensors are polarised, otherwise do this.
2. Select all (All) bioreactors from the selection bar.
3. In main menu Batch call up the start menu (Start All) of all
bioreactors.
4. Set the temperature setpoint and switch on the parameter.
5. Set the maximum expected stirrer speed during fermentation
and switch on the parameter.
6. Start the bioreactors.
7. Set the maximal expected gassing value during fermentation
for all bioreactors.
8. Wait until the required stirrer speed and operating temperature
have been achieved.
9. Wait until the medium in all bioreactors is saturated with oxy-
gen.
10. In main menu Batch, press Calibrate All pO2.
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The dialogue box Calibrate pO2 probes appears with:
Line 1 Select your reference value and press use as set
point
 Instruction Enter reference value, buttons 0%, 100%,
and display/input field Other: To select reference value
0 % or 100 % or to enter another value
 Use As SetPoint: To adopt reference value as setpoint
 Stop Use As SetPoint: To clear reference value as set-
point
For an explanation on the Use As SetPoint function refer to
chapter “Special Function USE AS SETPOINT”.
Line 2 Press Bior once the sensor data is stable
 Current Sensor Data: displays current measurements in
nA
 Instruction Press to confirm calibration and Bior A to
Bior F: To confirm each pO2 sensor measurement using
the relevant button.
 Restart calibration: To restart calibration.
 OK: To confirm calibration and close the dialogue box.
11. Press 100%.
The value is accepted in the view box/input field.
As soon as all measurements (Current Sensor data) are sta-
ble:
12. Press Bior A to Bior F one after another.
The values are accepted as 100 % oxygen saturation.
13. Press OK.
The dialogue box disappears, the calibration values are
stored.
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6.2.1.2 Calibrating all HAMILTON pO2 Sensors
In the following example a 100 % calibration of all (digital, optical)
HAMILTON pO2 sensors is performed. The 0 % calibration with
nitrogen of all pO2 sensors is not described in these instructions.
The procedure remains the same as described in the chapter “Calibrating
a HAMILTON pO2 Sensor”.
INFORMATION
If a 2-point calibration shall be carried out, the zero point (0 %)
must be calibrated first. The procedure remains the same as for a
single sensor.
Proceed as follows:
Procedure 1. Select all (All) bioreactors from the selection bar.
2. Call up the start menu of all bioreactors by pressing Start All.
3. Set the temperature setpoints and switch on the parameters.
4. Set the maximum expected stirrer speed during fermentation
and switch on the parameters.
5. Start the bioreactors.
6. Set the maximal expected gassing value during fermentation
for all bioreactors.
7. Wait until the required stirrer speed and operating temperature
have been achieved.
INFORMATION
pO2 sensors need 10 to 15 minutes to warm up after switching
on. In this phase they can measure. However, for optimum calibration
wait until after this period. If pO2 sensors are correctly
connected, the current pO2 value should be ≥1.0.
8. Call up main menu Batch and press Calibrate All pO2.
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The calibration menu Calibrate pO2 probe appears with:
Line 1: Place the probes into first buffer
 Information: The buffer’s value must be 0%-sat.
The zero point is pre-set and cannot be changed. The
zero point is always calibrated first when carrying out a 2point
calibration.
Lines 2 + 4: Press “Bior” button to calibrate sensor
 Bior A to Bior F: to start calibration of each pO2 sensor
by pressing its appropriate bioreactor button
Line 3: Place the probes into buffer and enter their reference
value in range xx.xxx … ...yyy.yyy %-sat. (Value displayed
in %-sat, the value is read by the sensor itself)
 Instruction Enter reference value
The value 100 (for 100 %) is pre-set in this input field and
is editable.
Footer
 Current Value: shows the current measured value
 Sensor Quality: charts the quality of the sensor in a
scale from 0 to 100 % in form of a display bar.
 Calibration Status: displays the calibration status
 OK: to exit the calibration menu.
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9. Wait until the medium is saturated with oxygen.
10. Press the input field in row 3 (if the value is not set to 100).
The numeric keypad appears.
11. Type in the value 100 and confirm with the OK key.
The value appears in the input field.
12. Press BiorA to BiorF one after another.
Progress bars of the calibration procedure appear instead of
the different buttons. The example to the left shows that the
pO2 sensors of bioreactor A and C are calibrated at the same
time i.e. progress of their calibration procedure is displayed.
13. Wait until calibration is complete.
Successful calibration is shown with OK in the Calibration Status
line.
In case of appearance of a number instead of OK: this indicates
an error which is a direct output of the sensors’s integrated
software from the sensor manufacturer HAMILTON.
INFORMATION
A list with error codes and their description can be found in chapter
“Error codes HAMILTON pO2 sensor calibration”.
14. In the calibration menu, press OK to close it.
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6.2.1.3 Error Codes Calibrating all HAMILTON pO2 Sensors
Error Code Description
01 Value to be calibrated at is too low
02 Value to be calibrated at is too high
04 Current temperature reading is too low
08 Current temperature reading is too high
10 Temperature reading is not stable
20 Phase is too low for the value to be calibrated at
40 Phase is too high for the value to be calibrated at
80 Phase reading during calibration is not stable
05 01 + 04
= Value to be calibrated at is too low
+ Current temperature reading is too low
09 01 + 08
= Value to be calibrated at is too low
+ Current temperature reading is too high
06 02 + 04
= Value to be calibrated at is too high
+ Current temperature reading is too low
0A 02 + 08
= Value to be calibrated at is too high
+ Current temperature reading is too high
11 01 + 10
= Value to be calibrated at is too low
+ Temperature reading is not stable
12 02 + 10
= Value to be calibrated at is too high
+ Temperature reading is not stable
INFORMATION
For detailed information about error codes contact the sensor
manufacturer HAMILTON.
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6.2.2 Calibrating the Zero Point of the Turbidity Sensor Optek-ASD
Due to the different light absorption characteristics of each medium,
a zero calibration of the turbidity sensor OPTEK-ASD should
be carried out before every fermentation/cultivation. Depending on
the application, this can be carried out before or after autoclaving.
Conditions for zero calibration of the sensor
The sapphire windows of the sensor must be clean and no air/gas
bubbles may adhere to them.
The light absorption of the medium prior to gassing and inoculation
can be used as the reference value for the zero point.
For details about technical data, use and maintenance refer to the
operating manual of the bioreactor.
Proceed as follows:
Procedure 1. Connect the sensor cable.
2. Call up the main menu Controller.
3. Wait until the measured value (parameter OD) is stable.
4. Call up the Calibrate option of the parameter.
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5. Press Calibrate in the calibration menu.
Calibration is started and a view bar appears to the right side
of the Calibrate button which charts the course of the calibration
.The progress is shown by a green colour.
If the view bar disappears after a few seconds, the calibration
is completed.
6. Press OK.
Calibration is saved, menu disappears.
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6.3 PID (Control)
The PID tab page is split into four horizontal areas and contains
input fields for PID control settings. The following table explains the
function of the individual setting values in more detail.
A detailed explanation of PID control with important notes for its
settings can be found in the following chapters.
Note the following:
 In the case of parameters which are not controlled but only
measured, only the value in the Eval Time (s) input field is relevant.
This value is always > 0.
 If the ramp output is switched off, the value in the Ramp Size
% input field is not relevant.
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Setting value Description
Prop. Term Proportional factor: The greater the discrepancy between the setpoint
value and the actual value the greater the controller output.
Integ. Term [1/s] The integral factor aggregates all errors over the time. If the setpoint
is not achieved using the proportional factor, the integral factor adjusts
the output successively until the setpoint value is achieved. An
integral factor set too high will lead to oscillation of the control loop.
Diff Term [s] The differential quotient calculates the change in the actual value
over the time and counteracts this change to limit any overshoot.
Neg. Factor The negative factor can be used to add weighting to two-sided control
(+100 to -100 %) (e.g. heavy acid, light alkali). In the process 1 is
the balance and 0.5 or 2 equate to the half or double the controller
output accordingly. Example: Nitrogen influences the pO2 value less
than oxygen, thus a negative factor of 2 can compensate for the reaction
of the controller.
Dead Band If a dead band is entered, no control is implemented within this value
at either side of the setpoint value (symmetrically, + / -). I.e. the controller
output is = 0. The dead band is used for pH control.
Integ. Limit [%] The integral influence is used to ensure that the integral factor cannot
increase over an indefinite period. This limits erroneous accumulation.
The integral influence is set between 0 and 100 % of the controller
output.
Ramp output In order to perform changes slowly or step-by-step, a ramp can be
introduced. This is useful above all for the stirrer speed or a mass
flow valve.
Ramp Size [%] The ramp size is a percentage value with which the controller output
is increased step-by-step and evenly over a set time. For the set
time see the value (in seconds) in the Eval Time input field.
Eval Time [s] The evaluation time determines the intervals in seconds at which the
PID value is recalculated. The controller speed is defined this way. A
scanning time of 10 seconds is a good average value.
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6.3.1 Explanations of PID Control
The PID function is based on a generic formula provided as exam-
ple:
Explanation of the formula
 Error = deviation between setpoint value and actual value.
 P = proportional factor, proportional response to an error,
used to reach a setpoint.
The bigger the value, the sharper the control.
 l = integral factor, integration of the error in 1/second.
A typical integral factor is < 0.05.
 D = differential quotient, derivative of the error, set in seconds
(mostly to 0).
Be aware of the following relating to the individual factors:
Proportional factor
The change of the proportional factor has a considerable effect on
a running process.
If the proportional factor is increased excessively, this causes oscillations
in the control loop around the setpoint value.
Example, the pH parameter
To achieve the setpoint value, a little acid, then a little base, acid
again, then base etc. is added.
If the proportional factor is reduced excessively, the controller
hardly reacts to the deviations and never achieves the setpoint
value.
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Integral factor
The integral factor should have a low value and only be changed a
little in small steps with long pauses.
The ideal approach is to switch off the equipment briefly after
changing the integral factor in order to delete the pending error cal-
culation.
A typical integral factor is < 0.05. It should equate to the reciprocal
value of double to quadruple the system’s cycle duration. The
higher the entered value, the less the time (in seconds) remains for
control.
A higher value than 0.05 is generally of no use as it exceeds the
time minimum for which the control is required. This causes fluctuations
in the control circuit.
Example of calculation of the integral factor
The cycle duration of system oscillations is measured at 50 seconds
from amplitude to amplitude. The integral factor is thus calculated
as follows:
1 / (50 sec x 2) = 0.01 1/sec
1 / (50 sec x 4) = 0.005 1/sec
Integral factor Seconds
01 10
0.05 20
0.001 100
0.005 200
Differential quotient
The differential quotient is rarely required. It is set to 0 (zero) at the
beginning.
A high value is only necessary if major changes are made in quick
succession. In all circumstances it causes the controller output to
react stronger.
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6.3.2 Changing the PID Controller Settings
ATTENTION
Inappropriate changes to the PID controller settings may have a
negative effect on the fermentation/cultivation process and cause
loss of property.
Only change factory settings of the PID controller(s), if you are
fully aware of the consequences or after consulting the manufac-
turer!
When making changes to the PID controller settings proceed as
follows:
Procedure 1. Make a note of the factory settings, i.e. make sure they can be
restored, if necessary.
2. For readjustment of a PID controller, start with the setting for
the proportional factor. Select a proportional band width as
large as possible.
3. Reset the integral factor and the differential quotient to zero.
4. Increase the proportional factor until the controller causes the
actual value to oscillate.
5. Measure the oscillation duration. E.g. with the diagram of the
parameter in the software from the equipment manufacturer.
6. Halve the proportional factor and vary the integral factor between
the reciprocal value of the doubled and quadrupled oscillation
duration.
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7 Cascade Control
The main menu Cascade provides the option of setting up a cascade
control of a process parameter – mostly pO2. This means
that the controller output parameter (=Output) of the master controller
(e.g. pO2) is used as a master parameter for the slave con-
troller(s).
INFORMATION
The master controller and slave controllers are also called master
and slave.
Serial cascade
A deviation of the setpoint of the parameter to be controlled (master
controller) influences the setpoint of the first parameter (slave
controller) in the cascade.
If the first parameter in the cascade reaches its maximum or minimum
setpoint and the setpoint of the parameter being controlled is
not yet achieved, the next parameter in the serial cascade is activated
and so it continues.
In the example of the left-hand figure:
The parameter Stirrer, the 1st slave controller, is activated first in
the cascade, to control the pO2 parameter, the master controller.
The parameter AirFlow, the 2nd slave controller, is only activated
when the setpoint of parameter pO2 has not been achieved by the
Stirrer parameter.
Parallel cascade
A deviation of the setpoint of the parameter to be controlled (master
controller) influences the setpoint of all parameters (slave controllers)
that are in the cascade.
In the example of the left-hand figure:
The parameters Stirrer and Air Flow, both slave controllers, are activated
at the same time to control the pO2 parameter, the master
controller.
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Parallel serial cascade
A deviation of the setpoint of the parameter to be controlled (master
controller) influences the setpoint of all parameters (slave controllers)
that are parallel and the first element in the cascade.
If the parameters that are connected in parallel reach their maximum
or minimum setpoint and the setpoint of the parameter being
controlled is not yet achieved, the next parameter(s) in the cascade
is/are activated.
In the example of the left-hand figure:
The parameters Stirrer and Air Flow (master controller) are activated
at the same time to control the pO2 parameter.
The parameter GasMix (slave controller) is only activated when the
setpoint of parameter pO2 has not been achieved by the Stirrer and
AirFlow parameters.
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7.1 Setting a Cascade
The different cascade settings are made in the left-hand side of the
main menu Cascade. The process parameters can be merged to a
cascade in the main area of the menu using drag & drop.
Cascade elements (parameters) can be removed and dropped off
in the recycle bin using drag&drop.
 Edit: to switch on/off the edit function of the cascade.
Switching off this function will also deactivate the display of
the present process parameters in the main area of the menu.
Once the edit function is switched on, all parameters can be
merged to one or even several cascades using drag&drop.
Each parameter can only be used once and in one cascade
only.
 Clear: to call up warning dialogue and delete cascade after
confirmation.
 Advanced: to switch on/off the setting mode for advanced cas-
cade.
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INFORMATION
Advanced cascades are used for customised equipment configurations.
They are only set from the equipment manufacturer at the
factory. Their settings and possible adjustments are equipmentspecific
saved at the factory. If required, they may be obtained
upon request from the manufacturer.
ATTENTION
Incorrect settings of an advanced cascade may have a negative
effect on the fermentation/cultivation process and cause loss of
property.
Only set or change an advanced cascade after consulting the
manufacturer and if you are fully aware of the consequences!
 Parameter name, (e.g. Stirrer): selected parameter with unit.
The selected parameter visually stands out from the other parameters
in the main screen area. The input fields for min./
max. and setpoint values are visible and enabled at the same
time to the left-hand side.
 Setp. Max. und Setp. Min.: factory settings for min. and max.
setpoint values which define the adjustable value range of the
selected parameter in which the cascade can change the setpoint
of the cascaded parameter to control the setpoint of the
master controller. These values are adjustable within this predefined
value range.
 Setpoint: setpoint of the parameter.
 Master controller: the setpoint to be controlled.
 Slave controller: the starting setpoint of the parameter
from which the setpoint of the parameter of the cascade
can be varied within the value range of Setp. Min. up to
Setp. Max.
INFORMATION
In most cases, it is recommended to set the setpoint for the slave
controller to the lower end of the value range (Setp. Min.)
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 Negative: to switch on/off the negative function of a cascade.
Can be used for slave controller, if an increase of the setpoint
of the slave controller leads to a decrease of the current value
of the slave controller.
 Output: to switch on/off the cascade and all used parameters
in the cascade hereby.
Each parameter in the cascade must be switched on (Output
ON) for the cascade to function.
The parameters can also be switched on and off in the Controller
main menu.
If a parameter is switched off (Output OFF), all of the following
parameters are uncoupled from the cascade.
Cascade progress display
A cascade and its progress can be seen in the Controller main
menu. In addition to arrows showing the direction of the cascade
control, the setpoint and the control output of the cascade that is
added to or subtracted from the setpoint is displayed in the Cascade
column. These values are given in the relevant parameter
unit.
The colour of the added/subtracted setpoint in the Controller menu
and the name of the parameter in the Cascade menu indicates the
progress of the cascade and the remaining scope of the cascade
within the value range of a slave controller to control the master
controller according to the following scheme:
Colour Utilisation of value range
Grey Inactive
Green 0 – 90 %
Yellow 90 – 99 %
Red 100 %
Blue 0 %
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Example of calculation
Stirrer, e.g. for slave controller from setpoint to max. setpoint.
 Setpoint: 500
 Setpoint max. 1200
 Value range: 1200 – 500 = 700
700 = 100 % / 630 = 90 %
500 + 630 = 1130 = setpoint, from which 90 % of the value range
are reached.
This means for the display according the colour scheme men-
tioned:
 Green: up to 1130
 Yellow: up to 1193
 Red: at 1200
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7.2 Deleting a Cascade
To delete all settings of a cascade (does not apply to advanced
cascade), proceed as follows:
Procedure 1. In main menu Cascade, press Clear.
A warning dialogue box appears with:
 Warning / Instruction: All information NOT created manually
with Advanced Cascades will be lost. Press OK to
confirm:
 OK: To confirm delete of the cascade and close the dialogue
box.
 Cancel: To close dialogue box without changes
2. Press OK.
Cascade is deleted.
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7.3 Negative Function of a Cascade
The Negative function causes a change in sign of the controller
output.
This means, a negative controller output causes the addition of a
positive value for the set point of the cascaded parameter and vice
versa.
The pH regulation with base and CO2 instead of acid is a classic
example of this: to reduce the pH, the CO2 flow rate (CO2Flow parameter)
needs to increase.
The fact that the Negative function has been switched on is illustrated
by the triangle symbol on the arrow that indicates the direction
of the cascade control.
This arrow shape can be seen both in the Cascade menu as well
as in the Controller menu.
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Cascade Control
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7.4 Special Configurations
For bioreactors with gassing strategy “High End” (configuration
with several mass flow controllers for flow control and gas mix) the
gases to be used e.g. Air Flow, N2 Flow and O2 Flow, must be assigned
to both parameters that control the gas mixture, i.e. parameters
GasMix and GM Flow, in the cascade configuration.
For this purpose, setup the following cascades additionally to the
desired cascade configuration, if the appropriate parameters are
present:
 Parameter Air Flow as slave controller to parameter GM Flow
 Parameter O2 Flow as slave controller to parameter GasMix
 Parameter N2 Flow as slave controller parameter GasMix
If parameters O2 Flow and N2 Flow are present, then they are
setup as a parallel cascade below parameter GasMix.
To make a distinction between the allocation of these parameters
and regular cascade elements, the connections are shown without
arrow.
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Pumps & Options
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8 Pumps & Options
The pumps are controlled in accordance with the corresponding
parameters:
 Acid (digital): in accordance with the pH parameter
 Base (digital): in accordance with the pH parameter
 Antifoam (digital): in accordance with the Antifoam parameter
 Feed (analogue): in accordance with the Feed parameter
 Optional extra analogue pump(s) which can be assigned to
one or two separate parameter(s) e.g. Feed 2 + 3.
Digital pumps have a set speed and are time controlled. I.e., they
always run at the same speed in start/stop mode. Analogue pumps
have a variable speed. Both digital and analogue pumps are controlled
within a range of 0 % to 100 %.
Example:
 Analogue: 50 % of the maximum feed rate = pump runs at half
speed.
 Digital: 50 % of the maximum feed rate = pump runs during
half the time
The following pump settings are possible:
 Setting the pump speed for feed pump(s) and dosing/waiting
time for the antifoam pump
 Calibrating the pumps
 Resetting the delivery rate manually to zero
 Filling or emptying the pumps and reagent hoses automati-
cally
For details on how to set the pump speed for the antifoam and feed
pumps see the chapters “Parameters”, “Antifoam” and “Feed”.
Calibration, pump counter and automatic filling and emptying of all
pump and reagent hoses is described in detail in the following
chapters.
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8.1 Calibrating a Pump
Calibrating a pump makes it possible to display and record the actual
delivered volume. The delivery rate is indicated in millilitres.
INFORMATION
Always use hoses of the same kind with the same dimensions for
calibration and pumping media.
Aids
 Graduated measuring cylinder/jug or scale/balance and an
empty vessel
 Reagent bottle equipped with silicone hose, filled with the reagent
to be delivered, the feed or a liquid which has the same
viscosity
INFORMATION
To obtain precise results, the reagent bottle should be put on a
scale which is linked to the bioreactor or to the bioprocess platform
software eve® installed on a PC or laptop.
Calibration
To calibrate a pump, e.g. the feed pump on bioreactor A, proceed
as follows:
Procedure 1. Connect the reagent bottle to the pump.
2. Place the output end of the hose in a measuring cylinder/jug.
Or: Place the reagent bottle on a scale and tare to zero, place
the output end of the hose in an empty vessel
3. Use the rocker switch of the pump to completely fill the hose.
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Note the following:
Press the rocker switch to the right
 Labfors 5 (figure to the left): the pump runs clockwise
 Multifors 2 (figure to the right): the pump runs counter
clockwise
INFORMATION
The same applies to both: if the reagent bottle is connected correctly,
the liquid is drawn from the reagent bottle and pumped towards
the culture vessel.
4. Select the desired bioreactor (in this case A) from the selection
bar I.e. the bioreactor whose pump you wish to calibrate.
5. Call up the main menu Batch (start menu) and press Feed
Pump.
The Calibrate Feed Pump dialogue box appears with:
Lines 1 to 3 with the following instructions
 Insert/prepare tube: Prepare the hose
 Push button to fill tube: Press and hold the rocker switch
to fill the hose.
 Tare balance (or empty measuring cup): tare the balance
or empty the measuring jug.
Line 4 Select pump speed and
 25%, 50%, 75%, 100% and input field %: To select the
pump speed in percent or enter another value in %.
After selecting one of the buttons, the Other button appears
instead of the % input field. Selection can be cancelled using
this button.
Line 5 Select calibration time
 30m, 1h, 6h, 12h and input field min: To select the calibration
duration or enter another calibration duration in
minutes.
Footer
 OK: To confirm entries and start calibration
 Cancel: To cancel procedure and close the dialogue
box without changes.
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6. Select the desired pump speed in % via the appropriate button
or enter it manually into the input field Other using the numeric
keypad.
INFORMATION
To obtain most accurate results, the pump should be calibrated at
the same speed as it is to be expected to run during fermenta-
tion/cultivation.
7. Select the desired calibration duration via the appropriate button
or enter it manually into the input field min. using the numeric
keypad.
8. Press OK.
Calibration starts. This and the remaining time in
hours/minutes/seconds are displayed with in progress and
time left... next to the available Stop button.
This button allows you to cancel the calibration process.
Once the time has elapsed:
the Bioreactor A, Calibrate Feed Pump Part 2 dialogue box
appears with:
 Enter Liquid Volume gr (or ml) input field: Enter the delivered
volume in mL or g.
 Pump Factor: Displays the calculated pump factor after
entry of the delivered volume.
The pump factor is always ≠ 1 with a calibrated pump.
 OK: To confirm entries.
 CANCEL: To cancel calibration and close the dialogue
box without changes.
9. Press the Enter Liquid Volume input field.
The numeric keypad appears.
10. Enter the delivered liquid in mL or g and confirm with the OK
key.
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The numeric keypad disappears; the value is adopted for the
input field.
The pump factor is calculated automatically and displayed in
the Pump Factor view box.
11. Press OK.
The dialogue box disappears; the calibration value is saved.
Done at with date and time next to the Stop button indicates
that and when the pump was cablibrated.
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8.2 Resetting the Pump Counter to Zero
The number of pump revolutions and the delivered quantity (in mL)
of calibrated pumps are displayed constantly during a running fermentation/cultivation
process. The display remains in place after
completion of the process (when the bioreactor is stopped) until a
new fermentation / cultivation process is started again (when the
bioreactor is started).
The counter can also be reset to zero manually, proceed as fol-
lows:
Procedure 1. Select the desired bioreactor from the selection bar, e.g. bioreactor
A.
2. Call up the main menu Main.
The delivered quantity (in mL) of the pumps is displayed on
the right-hand side of the screen.
3. Press the desired pump button, e.g. Feed.
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The Feed pump properties dialogue box appears with:
 Pump factor: Displays the pump factor or allows to be
changed manually.
The pump factor is always ≠ 1 with a calibrated pump.
 Duration: Displays number of pump revolutions
 Value: Displays delivered quantity in mL
INFORMATION
The values displayed here are fictitious and used only as an ex-
ample!
Manual change of the pump factor leads to rejection of the previous
calibration value.
 Reset: To switch on the reset of the pump counter
 Cancel: To close the dialogue box without changes
 OK: To confirm entry and close the dialogue box
4. Activate the counter reset via Reset.
The function is switched on.
5. Press OK.
The counter is reset to zero and the count starts from the beginning,
as soon as the bioreactor is started i.e. fermentation /
cultivation running.
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8.3 Automatically Filling/Emptying Pump Hoses
The Fill/Empty Pumps function allows the automatic filling or emptying
of all pump hoses. The function is available only if all bioreactors
are in stopped state.
The pumps are grouped by function, thus, for example, all acid
pumps are filled or emptied simultaneously without affecting the
base pumps etc. For each pump group, an individual filling duration
/ emptying duration can be defined.
WARNING
If the reagent bottles are not connected correctly, reagents may
emerge when filling the pump and reagent hoses!
WARNING
If acids and bases are directed into the same vessel when emptying
the pump and reagent hoses, chemical reactions may be
caused!
Note the following:
 The pump duration should preferably be tested with the liquid
which has the highest viscosity and the longest hose connec-
tion.
 Reagent hoses with the same function should be of the same
length and have the same filling volume. That means, for example,
that the same hoses of the same length are used for
all acid pumps etc.
To call up the menu, proceed as follows:
Procedure 1. Select all bioreactors (All) from the selection bar.
2. Call up main menu Batch and press Fill/Empty Pumps.
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The Fill/Empty Pumps dialogue box appears with:
 All pumps on four lines, grouped according their function
(All Acid Pumps etc).
 Two input fields Running time (sec) per pump group: To
enter the running duration of the pumps in seconds, either
for filling or for emptying
 Two buttons per pump group:
Fill: To start automatic filling
Empty: To start automatic emptying
Stop buttons are provided next to each of these buttons
for immediately stopping the filling or emptying process.
These buttons are not enabled until the respective process
has been started.
 OK: To close the menu / dialogue box.
INFORMATION
If a filling or emptying procedure is active, the remaining filling or
emptying duration is displayed. The menu / dialogue box cannot
be closed while at least one filling or emptying procedure is ac-
tive.
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Starting & Stopping the Bioreactor(s)
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9 Starting & Stopping the Bioreactor(s)
A single bioreactor is started and stopped via Start and Stop in
main menu Batch of the selected bioreactor.
If more than one bioreactor is controlled via touch screen software,
then all stopped or running bioreactors can be started or stopped
at once via Start All / Stop All after selecting all (All) bioreactors in
the selection bar
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Starting & Stopping the Bioreactor(s)
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9.1 Starting a Bioreactor
To start a bioreactor (= 1 culture vessel) proceed as follows:
Procedure 1. Select the desired bioreactor from the selection bar, e.g. bioreactor
A.
2. In main menu Batch, press Start.
The Start bioreactor A operation (start dialogue) appears with
all present parameters. This is where the setpoint value settings
for the parameters of the last fermentation/cultivation
process are visible.
INFORMATION
The bioreactor is started with the settings in the start dialogue.
Changes to these settings are saved and transferred to the next
start dialogue. If setpoint values are changed or parameters are
switched on/off whilst a bioreactor is running, these settings are
only adopted for the current fermentation process.
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3. Set the desired setpoint values and switch on all required pa-
rameters.
For details on the start dialogue and setpoint value settings /
switching parameters on/off refer to chapter “Parameter Options”,
Setting Setpoint Values, Switching Parameters ON
/OFF”.
4. Press OK.
The bioreactor starts.
Start is no longer enabled, but Stop is available now. The display
in progress since indicates, that and for how long the bioreactor
has been running in hours/minutes/seconds.
Current values and controller outputs for the parameters are visible
in the main menu Controller.
A recording of the current values and a diagram are visible in the
main menu Trends.
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9.2 Stopping a Bioreactor
To stop a running bioreactor (= 1 culture vessel) proceed as fol-
lows:
Procedure 1. Select the desired bioreactor from the selection bar, e.g. bioreactor
A.
2. In main menu Batch, press Stop.
The Confirmation dialogue box appears with:
 Information: Bioreactor will be stopped.
 Instruction: Press OK to confirm
 OK: To stop the bioreactor and close the dialogue box.
 Cancel: To cancel and close the dialogue box without
changes.
3. Press OK.
The dialogue box disappears, the bioreactor stops.
Stop is no longer enabled. The display stopped after indicates
that and after how much time the bioreactor was stopped.
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9.3 Starting all Bioreactors
To start all stopped bioreactors, proceed as follows:
Procedure 1. Select all bioreactors from the selection bar.
2. In main menu Batch, press Start All.
The Start ALL bioreactor operation (start dialogue) dialogue box
appears with all present parameters. This is where the setpoint
value settings for the parameters of the last fermentation processes
are visible.
INFORMATION
All bioreactors are started with the settings in the start dialogue.
Changes to these settings are saved and transferred to the next
start dialogue. If setpoint values are changed or parameters are
switched on/off whilst bioreactors are running, these settings are
only adopted for the current fermentation process.
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3. Set the desired setpoint values for the parameters and switch
on all required parameters.
For details on the start dialogue and setpoint value settings /
switching parameters on/off refer to chapter “Parameter Options”,
Setting Setpoint Values, Switching Parameters ON
/OFF”.
4. Press OK.
All the bioreactors are started.
Start All is no longer enabled, but Stop All is available now.
For every single bioreactor, the display in progress since indicates,
that and for how long the bioreactor has been running
in hours/minutes/seconds.
Current values and controller outputs for the parameters are visible
in the main menu Controller of each bioreactor. A recording of the
current values and a diagram are visible in the main menu Trends
of each bioreactor.
There exists no complete view of all bioreactors.
All running bioreactors can be individually stopped only one by one
or all at once.
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9.4 Stopping all Bioreactors
To stop all running bioreactors at once, proceed as follows:
Procedure 1. Select all bioreactors from the selection bar.
2. In main menu Batch, press Stop All.
The Confirmation dialogue box appears with:
 Information: All bioreactors will be stopped.
 Instruction: Press OK to confirm.
 OK: To stop all bioreactors and close the dialogue box.
 Cancel: To cancel and close the dialogue box without
changes.
3. Press OK.
The dialogue box disappears, all bioreactors are stopped.
Stop All is no longer enabled. Start All is enabled again.
The display stopped after indicates for every single bioreactor
that and after how much time the bioreactor was stopped.