Sartorius Stedim Biotech BIOSTAT B-DCU User manual

85037-549-98
Operating Instructions
(Translation of the Original Operating Instructions)
BIOSTAT
®B-DCU
Bioreactor | Fermenter

BIOSTAT
®B-DCU Operating Instructions 3
Contents
Contents
1 About These Instructions ..............................................8
1.1 Validity ..........................................................8
1.2 Accompanying Documents ..........................................8
1.3 Target Groups.....................................................9
1.4 Symbols Used ....................................................10
1.4.1 Warnings .................................................10
1.4.2 Other Symbols Used ........................................10
2 Safety Information...................................................11
2.1 Intended Use.....................................................11
2.2 Qualification of Personnel .........................................11
2.3 Significance of These Instructions ...................................11
2.4 Proper Working Order of the Device .................................11
2.5 Safety Devices ...................................................12
2.5.1 Electrical Power ...........................................12
2.5.2 Energy Release ............................................12
2.5.3 Gases ....................................................12
2.6 Accessories, Consumables, and Spare Parts............................13
2.7 What to Do in the Event of an Emergency ............................13
2.8 Personal Protective Equipment .....................................14
2.9 Components under Pressure........................................14
2.10 Escaping Substances ..............................................15
2.11 Hot Surfaces.....................................................15
2.12 Unintended or Unexpected Startup of the Device......................15
2.13 Rotating or Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.14 Danger of Tripping or Slipping......................................16
3 Device Description ...................................................17
3.1 Device Overview..................................................17
3.1.1 Control Unit ..............................................18
3.1.2 Supply Unit ...............................................20
3.1.2.1 Front View (with/without Variable Area Flow Meter) ....20
3.1.2.2 Front View of Connection Panel .....................21
3.1.2.3 Rear View of Connection Panel ......................22
3.1.2.4 Rear View ........................................23
3.1.3 Aeration..................................................23
3.1.3.1 Variable Area Flow Meter ...........................24
3.1.3.2
"O2Enrichment” and “Gasflow Ratio” Aeration Modules ..25
3.1.3.3 "Advanced Additive Flow” Aeration ..................26
3.1.4 Peristaltic Pumps ..........................................27
3.1.4.1 Integrated Peristaltic Pumps ........................28
3.1.4.2 External Pumps ...................................29
3.1.5 Temperature Control Modules ...............................29
3.1.5.1 Temperature Control Module for Double-Walled
Culture Vessels....................................29
3.1.5.2 Temperature Control Modules for Single-Walled
Culture Vessels....................................30
3.1.6 Culture Vessels ............................................30
3.1.6.1 Stirrer Drive ......................................31
3.2 Safety Devices and Protective Systems ...............................32
3.2.1 Mains Disconnector ........................................32
3.2.2 Overpressure Valves and Pressure Reducers ....................32
3.2.2.1 Aeration Segment Overpressure Valves ...............32
3.2.3 Overheating Protection .....................................33
3.3 Symbols on the Device ............................................33
3.4 Manufacturer’s ID Labels...........................................34

4 BIOSTAT
®B-DCU Operating Instructions
Contents
4 Software............................................................35
4.1 User Information .................................................35
4.2 System Start .....................................................35
4.3 Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
4.3.1 User Interface .............................................36
4.3.1.1 Header ..........................................37
4.3.1.2 Work Area .......................................37
4.3.2 Footer....................................................38
4.3.3 Display of Function Elements ................................40
4.3.4 Overview of the Main Function Keys ..........................41
4.3.5 Overview of Selection Keys ..................................42
4.3.6 Direct Function Keys for Selection of Submenus ................42
4.3.7 Selection Lists and Tables ...................................45
4.4 Password Protection of Individual Functions ..........................45
4.5 User Management ................................................46
4.6 Bug Handling and Troubleshooting ..................................46
4.7 Locking Functions ................................................46
5 Transport ...........................................................47
5.1 Inspection upon Acceptance by the Recipient .........................47
5.1.1 Reporting and Documenting Transport Damage.................47
5.1.2 Checking Completeness of the Delivery........................47
5.2 Packaging .......................................................47
5.3 Shipping Instructions .............................................47
6 Installation..........................................................49
6.1 Ambient Conditions...............................................49
6.2 Work Surfaces and Loads ..........................................49
6.3 Laboratory Energy Sources .........................................50
6.3.1 Electricity.................................................50
6.3.2 Temperature Control Medium................................51
6.3.3 Gas Supply................................................52
7 Getting Started......................................................53
7.1 Installation Materials..............................................53
7.2 Connecting the Control Unit .......................................53
7.2.1 Connecting the Control Unit to an External Host System.........53
7.2.2 Connecting Network-Compatible Components to the
Control Unit ..............................................54
7.3 Connecting the Supply Unit ........................................54
7.3.1 Connecting the Supply Unit to the Control Unit ................54
7.3.2 Connecting Network-Compatible Components to the
Supply Unit ...............................................54
7.3.3 Connecting Additional Components/Sensors to the Supply Unit ...54
7.3.4 Connecting the Laboratory’s Water Supply to the Supply Unit ....55
7.3.5 Connecting the Laboratory’s Gas Supply to the Supply Unit ......55
7.3.6 Connecting Stirrer Drive ....................................56
7.3.7 Connecting the Hoses for Aeration ...........................57
7.3.8 Connecting the UniVessel®SU Holder .........................57
7.3.9 Connecting the Barcode Scanner .............................58
7.4 Connecting the Temperature Control System..........................58
7.4.1 Double-Walled Culture Vessels/Single-Walled Culture Vessels
with Heating/Cooling Jacket.................................58
7.4.2 Heating jacket.............................................60
7.5 Connecting the Exhaust Cooling Hoses...............................62
7.6 Connecting External Pumps ........................................62
7.7 Connecting the Balance ...........................................63
7.8 Switching the Control Unit and Supply Unit(s) On/Off ..................64

BIOSTAT
®B-DCU Operating Instructions 5
Contents
8 Preparing and Running the Process ....................................65
8.1 Overview ........................................................65
8.2 Preparing the Glass Culture Vessels ..................................65
8.3 Connecting Transfer Lines..........................................66
8.4 Preparing the Cultivation Process ...................................67
8.4.1 Mounting the Stirrer Drive ..................................68
8.4.2 Installing the Heating/Cooling Jacket .........................70
8.4.3 Connecting the Aeration Modules ............................71
8.4.3.1 Conducting Preliminary Steps .......................71
8.4.3.2 UniVessel®SU Safety Valve Station ...................71
8.4.3.3 Connecting the “O2Enrichment” and “Gasflow Ratio”
Aeration Modules .................................72
8.4.3.4 Connecting the “Advanced Additive Flow”
Aeration System ..................................72
8.4.4 Preparing the Corrective Medium Supply ......................73
8.5 Performing a Process..............................................76
8.5.1 Setting Up the Measurement and Control System...............76
8.5.2 Guarantee Sterility.........................................76
8.5.3 Alternating Operation between Glass Culture Vessel and
UniVessel®SU .............................................77
8.5.4 Carrying Out the Cultivation Process..........................77
8.6 “Main” Menu ....................................................78
8.6.1 General Information........................................78
8.6.2 Process Displays in the “Main” Menu..........................79
8.6.3 Direct Access to Submenus ..................................79
8.7 “Trend” Menu ....................................................81
8.7.1 Trend Display..............................................81
8.7.2 Changing the Settings for a Channel..........................82
8.7.2.1 Assigning a Process Value to a Channel ...............83
8.8 “Calibration” Menu ...............................................84
8.8.1 General Information........................................84
8.8.2 Group or Single Calibration..................................85
8.8.3 pH Calibration (Conventional Sensor) .........................86
8.8.3.1 General Information on pH Sensors ..................86
8.8.3.2 “Calibration pH-#” Submenu........................87
8.8.3.3 Performing Calibration.............................88
8.8.3.4 Direct Input of the Zero Offset and Slope .............89
8.8.3.5 Perform recalibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
8.8.4 pH Calibration (Digital Sensor) ...............................89
8.8.4.1 General Information on pH Sensors ..................89
8.8.4.2 “Calibration pH-B#” Submenu.......................90
8.8.4.3 Performing Calibration.............................91
8.8.4.4 Direct Input of the Slope ...........................92
8.8.4.5 Perform recalibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
8.8.5 DO (pO2) Calibration (Conventional Sensor) ....................94
8.8.5.1 General Information on the DO (pO2) Sensors ..........94
8.8.5.2 “Calibration pO2-#” Submenu .......................94
8.8.5.3 Performing Calibration.............................95
8.8.5.4 Direct Input of the Zero Offset and Slope .............96
8.8.6 DO (pO2) Calibration (Digital Sensor) ..........................96
8.8.6.1 General Information on the digital DO (pO2) Sensors ....96
8.8.6.2 “Calibration pO2-B#” Submenu ......................97
8.8.6.3 Performing Calibration.............................98
8.8.7 Optical pH and DO (pO2) Sensors ............................100
8.8.7.1 Signal Quality of the Optical Probes.................100
8.8.7.2 Notes on Calibration..............................101
8.8.8 pH Calibration (Optical Sensor)..............................101
8.8.8.1 “Calibration pH-#” Submenu.......................102
8.8.8.2 Entering Initial Calibration Data ....................103

6 BIOSTAT
®B-DCU Operating Instructions
Contents
8.8.8.3 Performing Recalibration ..........................104
8.8.8.4 Configuring the Measurement Cycle for
pH Measurement.................................105
8.8.9 DO (pO2) Calibration (Optical Sensor).........................106
8.8.9.1 “Calibration pO2-#” Submenu......................106
8.8.9.2 Performing Initial Calibration ......................107
8.8.9.3 Performing Recalibration ..........................108
8.8.9.4 Configuring Measurement Cycles for DO (pO2)
Measurement....................................108
8.8.10 Totalizer for Pumps and Valves..............................109
8.8.11 Balance Taring ...........................................111
8.8.12 Redox Calibration.........................................112
8.8.13 Turbidity Calibration ......................................113
8.8.14 Setting the Speed of the Internal Analog Pumps ...............114
8.9 “Controller” Menu ...............................................115
8.9.1 Functional Principle and Equipment .........................115
8.9.2 Controller Selection .......................................116
8.9.3 General Controller Operation ...............................116
8.9.4 Setpoint Profiles..........................................117
8.9.5 General Controller Parameterization .........................119
8.9.5.1 Output Limits....................................119
8.9.5.2 Dead Zone ......................................119
8.9.5.3 Controller Parameterization Menu Screen ............120
8.9.5.4 PID Parameters ..................................120
8.9.5.5 PID Controller Optimization........................120
8.9.6 Guide and Slave Controller (TEMP, JTEMP) Temperature
Measurement ............................................121
8.9.7 Speed regulation (STIRR) ...................................122
8.9.8 Anti-foam Controller (FOAM) ...............................124
8.9.9 Level Control with Level Sensor (LEVEL).......................125
8.9.10 Adjusting the “VWEIGHT” Gravimetric Level Controller..........126
8.9.11 Adjusting the “FLOW” Gravimetric Filling Pump Controller.......127
8.9.12 Filling Pump Controller (SUBS) ..............................128
8.9.13 Adjusting Gas Controllers ..................................128
8.9.14 Adjusting the pH Controller ................................129
8.9.15 DO (pO2) Regulation Methods...............................132
8.9.15.1 Adjusting the DO (pO2) Sensor Process Value Source ...133
8.9.15.2 DO (pO2) Controller CASCADE (Cascade Controller) ....134
8.9.15.3 DO (pO2) Controller ADVANCED (Polygon Controller)...136
8.9.16 Using Pumps from pH, Foam, and Level Control for
Substrate Addition ........................................143
8.9.17 Glucose Controller (GLUCO) ................................145
8.9.18 Customer-Specific Changes to Controllers ....................145
8.10 “Settings” Menu.................................................146
8.10.1 General Information.......................................146
8.10.2 Changing System Settings..................................147
8.10.3 Measuring Range Settings..................................148
8.10.4 Manual Operation ........................................149
8.10.4.1 Manual Operation for Digital Inputs.................149
8.10.4.2 Manual Operation for Digital Outputs ...............151
8.10.4.3 Manual Operation for Analog Inputs ................152
8.10.4.4 Manual Operation of Analog Outputs ...............153
8.10.4.5 Manual Operation for Controllers (“Control Loops”)....154
8.10.5 Manual Operation of Sequence Control (“Phases”) .............155
8.10.6 Externally Connected Devices ...............................156
9 Cleaning and Maintenance...........................................157
9.1 Cleaning .......................................................157
9.1.1 Cleaning the Device .......................................158
9.1.2 Cleaning the Culture Vessels ................................158

BIOSTAT
®B-DCU Operating Instructions 7
Contents
9.2 Maintenance....................................................158
9.2.1 Maintenance Info.........................................158
9.2.2 Maintenance Schedule.....................................159
9.2.3 Carrying Out Maintenance Work on Safety Components ........160
10 Faults..............................................................161
10.1 Procedure ......................................................161
10.2 Hardware-related Faults ..........................................161
10.2.1 “Contamination” Troubleshooting Table ......................161
10.2.2 “Counter Cooling System” Troubleshooting Table ..............162
10.2.3 “Aeration and Ventilation” Troubleshooting Table ..............162
10.3 Process-related Faults/Alarms .....................................163
10.3.1 Alarm Triggering..........................................163
10.3.2 “Alarm Overview” Menu ...................................164
10.3.3 Process Value Alarms ......................................164
10.3.4 Alarms for Digital Inputs ...................................166
10.3.5 Alarms, Meaning, and Corrective Measures....................168
10.3.5.1 Process Alarms...................................168
10.3.5.2 Process Messages.................................168
10.3.5.3 System Alarms ...................................168
11 Disposal............................................................169
11.1 General Information .............................................169
11.2 Information on Decontamination ..................................169
11.3 Decommissioning the Device ......................................170
11.4 Dismantling the Device ...........................................171
11.5 Disposal........................................................171
12 Storage and Shipping ...............................................172
12.1 Storage ........................................................172
12.2 Storage Conditions ..............................................172
12.3 Packing/Return..................................................172
12.3.1 General Information.......................................172
12.3.2 Returning the Device ......................................172
13 Technical Specifications .............................................173
13.1 Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
13.1.1 Dimensions ..............................................173
13.1.2 Mains connection.........................................173
13.2 Supply Unit.....................................................173
13.2.1 Dimensions ..............................................173
13.2.2 Mains Connection (120 V Version) ...........................173
13.2.3 Mains Connection (230 V Version) ...........................173
13.2.4 Work Surface for 6 Supply Units ............................174
13.3 Energy Connections Inside the Laboratory ...........................174
13.3.1 Cooling Water Supply/Cooling Circuit ........................174
13.3.2 Process Gas Supply........................................174
13.4 Temperatures in the UniVessel®....................................175
13.5 Stirrer Drive ....................................................175
13.6 External Pumps .................................................175
13.7 Ambient Conditions..............................................176
13.8 Calculating Water Hardness .......................................176
13.9 Dimensions of the Variable Area Flow Meters ........................177
14 Conformity & Licenses...............................................178
14.1 GNU Licensing ..................................................178
14.2 Conformity Documents ...........................................178
15 Appendix...........................................................182
15.1 Pin Assignment Female Connectors.................................182
15.2 Decontamination Declaration......................................184

8 BIOSTAT
®B-DCU Operating Instructions
About These Instructions
1 About These Instructions
1.1 Validity
These instructions provide all the information needed to operate the
BIOSTAT
®B-DCU (referred to as the “device” in the following). These instructions
apply to the following versions of the device:
BIOSTAT
®B-DCU device Type
Control unit 1000012248
Supply unit 2 gas outputs 1000012304
Supply unit 6 gas outputs 1000012305
These instructions apply to the BIOSTAT
®B-DCU in combination with the following
components:
Component Description
UniVessel®Glass, single-walled 1L, 2L, 5L, 10L
UniVessel®Glass, double-walled 1L, 2L, 5L, 10L
UniVessel®SU 2L
1.2 Accompanying Documents
These instructions provide information for operating the device with the standard
equipment intended for this purpose.
t In addition to these instructions, observe the following documentation:
− Operating instructions for UniVessel®Glass culture vessels
− Operating instructions for UniVessel®SU culture vessels and associated
components, e.g., UniVessel®SU holder, adapter ring, connection box
− Instructions for electrodes, e.g., pH electrode
− Technical documentation in the “Technical Documentation” folder, e.g.,
P&I diagrams, spare parts list, installation plans, technical drawings, etc.
− Documentation for customer-specific modifications (if applicable)
− Operating instructions for DCU4 system user management
− Operating instructions for DCU4 system logbook function
− Operating instructions for DCU4 system parameter import/export
− Operating instructions for BioPAT Xgas
− Operating instructions for BioPAT Trace
− Operating instructions for BioPAT ViaMass
− Operating instructions for DeltaV connection

BIOSTAT
®B-DCU Operating Instructions 9
About These Instructions
1.3 Target Groups
These instructions are designed for the following target groups. The target groups
must possess the knowledge listed.
Target group Knowledge | responsibilities
User The user is familiar with the operation of the device and
the associated work processes. He knows the dangers that
can occur when working with the device and can avoid
these dangers.
The user has been trained in the operation of the device.
The training takes places within the scope of startup and is
performed by the laboratory manager or device operator.
Operating engineer |
laboratory manager
The operating engineer | laboratory manager makes
decisions about the use and configuration of the device.
The operating engineer | laboratory manager is trained in
the operation of the device. The training takes place
during startup and is performed by Sartorius Service or the
operator.
Administrator The Administrator is responsible for integrating the
device in the production process. He ensures the reliable
functioning of the system and device software.
The administrator is trained in the operation of the device.
The training takes place during startup and is performed
by Sartorius Service or the operator.
Electrician An electrician has the specialized training, knowledge, and
experience as well as familiarity with applicable standards
and regulations to evaluate the work assigned to him or
her and identify possible hazards.
Operator The device operator is responsible for ensuring compliance
with workplace health and safety regulations.
The Operator must ensure that anyone working with
the device has access to the relevant information and is
trained to work with the device.

10 BIOSTAT
®B-DCU Operating Instructions
About These Instructions
1.4 Symbols Used
1.4.1 Warnings
WARNING
Denotes a hazard that may result in death or (severe) injury if it is not avoided.
CAUTION
Denotes a hazard that may result in moderate or minor injury if it is not avoided.
ATTENTION
Denotes a hazard that may result in material damage if it is not avoided.
1.4.2 Other Symbols Used
t
Required action: Describes actions which must be carried out in the order given.
y Describes the result of the actions.
[ ] Refers to control and display elements.
Figures on the Operating Display
Depending on your device configuration, the figures on the operating display of your
device may deviate from those in these instructions.

BIOSTAT
®B-DCU Operating Instructions 11
Safety Information
2 Safety Information
2.1 Intended Use
The device is used as the control unit for various bioreactor systems in combination
with the UniVessel®Glass or UniVessel®SU. This control unit is used to cultivate
biological cultures in liquids or aqueous nutrient solutions under controlled and
reproducible conditions. For this purpose, the medium is stirred and kept under
prescribed cultivation conditions. The device is exclusively designed for this purpose.
The device is not suitable for use in potentially explosive environments.
The device may only be used indoors.
These instructions are part of the device. The device is intended exclusively for use in
accordance with these instructions.
Foreseeable Misuse
Any use going beyond the intended use of the device may lead to unknown hazards
and falls under the sole responsibility of the operator.
No misuse is reasonably foreseeable.
2.2 Qualification of Personnel
All persons working with the device must have the required knowledge to do so
(see Chapter “1.3 Target Groups,” page 9).
The activities described in these instructions are intended for the User target group.
If individual tasks have to be carried out by other target groups, this is specified in
the instructions.
Sartorius Service
Information with service addresses and services offered can be found on our website
(www.sartorius.com).
2.3 Significance of These Instructions
These instructions must be read, understood and used by all personnel commissioned
to work with the device. Failure to observe these instructions can have serious
consequences, such as hazards to personnel from electrical, mechanical, or chemical
influences.
t Before working with the device: Read these instructions carefully and thoroughly.
t If these instructions are lost: Request a replacement or download the latest
version from our website.
t The information from these instructions must be available to users.
2.4 Proper Working Order of the Device
A damaged device or worn parts may lead to malfunctions or cause hazards which
are difficult to recognize.
t Only operate the device when it is safe and in perfect working order.
t Observe the maintenance intervals (for intervals and maintenance work,
see Chapter “9 Cleaning and Maintenance,” page 157).
t Have any malfunctions or damage repaired immediately by the Sartorius Service.

12 BIOSTAT
®B-DCU Operating Instructions
Safety Information
2.5 Safety Devices
The safety devices of the device protect personnel working with the device from
hazards caused by the device, e.g., electrical current.
t Do not remove or modify the safety devices (for safety devices, see Chapter 3.2,
page 32).
2.5.1 Electrical Power
Electrical switching elements are installed in the device. Damage to the insulation or
individual components can be fatal. Contact with parts under voltage represents a
direct danger of death.
Work on and modifications to the electrical equipment of the device may only be
carried out by Sartorius Service personnel. The device may only be opened by
Sartorius Service personnel.
t Check the device for defects such as loose connections or damage to the
insulation (for intervals and service tasks, see Chapter “9 Cleaning and
Maintenance,” page 157).
t Keep moisture away from parts under voltage. Moisture can lead to short circuits.
t Switch off the power supply immediately if defects with the electrical equipment
are discovered and contact Sartorius Service.
t Do not replace the power supply cable with a power supply cable of insufficient
length. Only use the original power supply cable.
2.5.2 Energy Release
Power supply lines may be incorrectly dimensioned and not protected against
impermissible fluctuations and faults. This can lead to energy release, e.g., electrical
shock or gas release.
The power supply lines for operating the device must meet the Specifications
(see Chapter 13, page 173). Energy connections must be fitted with fully functional
safety devices:
− Earth leakage circuit breaker for mains connections (ground fault circuit
interrupter)
− Fittings for shutting off water, compressed air or gas supplies
2.5.3 Gases
Gases used in the cultivation process or produced by the culture can be dangerous;
there is a risk of suffocation due to nitrogen and carbon dioxide, for example.
All gas lines used in the cultivation process must be checked regularly for leaks
(Chapter “9 Cleaning and Maintenance,” page 157).
t Observe the applicable workplace health and safety information to protect
against gases, e.g., for information on the handling and storage of gases and
what to do in the event of an emergency.
t Ensure that the workplace is well ventilated.
t If required: Connect the exhaust air from the cultivation process to a laboratory
exhaust air treatment system.
t If required: Outfit the room with suitable equipment for monitoring the air.
Risk of explosion and fire due to pure oxygen (O2)
Pure oxygen can give rise to chemical reactions that could cause substances to
self-combust. Areas where pure oxygen can escape must be ventilated so that the air
cannot be saturated with pure oxygen.

BIOSTAT
®B-DCU Operating Instructions 13
Safety Information
The oxygen line from the gas source to the consumption point must be free from
grease and oil. The oxygen line comprises all areas where pure oxygen is routed or
that are saturated with pure oxygen.
t Use only grease and oil-free gases in the cultivation process.
t When working on the oxygen line: Make sure your work equipment and hands
are free of dust and oil.
t Keep pure oxygen away from flammable materials and ignition sources.
t Avoid sparks in the vicinity of pure oxygen.
2.6 Accessories, Consumables, and Spare Parts
The use of unsuitable accessories, consumables and spare parts can be hazardous and
have the following consequences:
− Damage to the device
− Malfunctions of the device
− Device failure
t Only use accessories, consumables, and spare parts supplied by Sartorius.
Information on operational quality is available upon request from Sartorius.
t Only use accessories, consumables, and spare parts that are in proper working
order.
2.7 What to Do in the Event of an Emergency
Device malfunctions can lead to injury or material damage.
Immediately decommission the device if there is a direct risk of injury to personnel
or damage to the device:
Control Unit
t Firmly pull out the connection cable from the “Mains In” socket.
Supply Units
t Turn the main switch (1) to position 0(Off).
y The power supply to the device is disconnected.
y The inlet-side pressures in the gas lines are retained.
y The pressures to the culture vessel will reduce on their own.
t Have faults rectified immediately by Sartorius Service.
1
1

14 BIOSTAT
®B-DCU Operating Instructions
Safety Information
2.8 Personal Protective Equipment
Personal protective equipment protects against hazards caused by the device or the
processed materials.
Protective equipment Explanation/examples
Protective work
clothing
Tight-fitting work clothing with low tear resistance, tight
sleeves, and without any projecting parts. / Protects users
from getting caught by moving parts.
Head covering Protects the hair from getting pulled into moving parts.
Safety gloves Protect against chemicals, heat and injuries.
Safety glasses Protect against substances leaking under high pressure,
splashing liquids.
Safety boots |
non-slip shoes
Protect against injuries to the feet caused by mechanical
effects. | Protect against slipping on wet surfaces.
t Wear appropriate personal protective equipment.
t Also follow the instructions posted in the work area pertaining to personal
protective equipment.
2.9 Components under Pressure
Bursting of the Glass Culture Vessel
If the culture vessel is put under excessive pressure, it may burst, e.g., if gas supply
equipment from third-party manufacturers is used or if the exhaust filter gets
blocked. Damaged or bursting culture vessels can cause cuts and pose a risk of injury
to the eyes.
t Only use the control and supply unit for gas supply. The pressure safety valve
installed in the supply unit limits the operating pressure in the glass culture
vessel to max. 1 bar.
t Ensure that the supply lines for compressed air and gas comply with the device
specifications.
t The total volumes of all liquid media to be supplied should be less than the air
volumes in the culture vessel.
t Always use the exhaust cooler in the cultivation process. The exhaust cooler
protects the exhaust filter from getting blocked.
Bursting of the UniVessel®SU Culture Vessel
If the culture vessel is put under excessive pressure, it may burst, e.g., if gas supply
equipment from third-party manufacturers is used or if the exhaust filter gets
blocked. Damaged or bursting culture vessels can cause cuts and pose a risk of injury
to the eyes.
t Use the safety valve station when using the UniVessel®SU.
t Always use the filter heater in the cultivation process. The filter heater protects
the exhaust filter from getting blocked.
t The total volumes of all liquid media to be supplied should be less than the air
volumes in the culture vessel.

BIOSTAT
®B-DCU Operating Instructions 15
Safety Information
2.10 Escaping Substances
Faulty Components
If individual components are damaged, gaseous and liquid substances may escape
under high pressure and cause injury to the eyes, for example.
t Do not start the device without overpressure valves and pressure reducer or
comparable overpressure safety devices (such as a burst disk).
t Have overpressure valves and the pressure reducer serviced regularly by Sartorius
Service.
t When working on components under pressure: Switch off the device and secure
it from being turned back on again.
t Regularly check all lines, hoses, and connections under pressure for leaks and
externally detectable damage.
t Only switch on pump when the pump head is closed.
Escaping Supply and Culture Media
Escaping supply and culture media can lead to chemical burns and contamination.
Take special measures when working with supply and culture media that pose a
health risk.
t Only use prescribed hoses.
t Use hose fastenings on connecting pieces.
t Clear supply hoses.
t When loosening hose connections: Wear personal protective equipment.
2.11 Hot Surfaces
Contact with hot surfaces poses a burn risk.
t Avoid contact with hot surfaces, such as:
− Temperature-controlled heating mats
− Motor housing
− Culture vessel
− Heating module.
t Allow heating elements and device equipment to cool.
t Wear personal protective equipment.
2.12 Unintended or Unexpected Startup of the Device
The device may start up automatically to the preset parameters after a power failure,
depending on the settings on the control and supply unit.
t Observe the information on device behavior after a power failure
(see Chapter “4.2 System Start,” page 35).
2.13 Rotating or Moving Parts
Clothing or body parts can get caught if they come into contact with rotating
or moving parts, such as the stirrer shaft of the culture vessel. This can lead to
dangerous injury.
t Wear personal protective equipment.
t Only start the stirrer drive when it is positioned on and fixed to the stirrer shaft.
t Only switch on the stirrer drive when the UniVessel®is fully mounted.
t Only switch on the pump when the pump head is closed.

16 BIOSTAT
®B-DCU Operating Instructions
Safety Information
2.14 Danger of Tripping or Slipping
Power supply cables that are too long may present a tripping hazard. Hoses that are
too long and not secured may present a tripping hazard. Disconnected hoses may
cause the floor to become soiled (hose leakages). This poses a risk of slipping.
Therefore:
t Ensure that power supply cables are properly laid.
t Install the reservoir bottles as close as possible to the basic unit.
t Keep hoses as short as possible.
t Check hoses before inserting and startup:
− Check general condition of the hose
− Ensure hoses are sufficiently fastened to the hose barbs. If necessary, also
secure hoses with cable ties.
t Ensure the hoses are properly laid:
− No kinks in the hoses.
− No twists in the hoses.

BIOSTAT
®B-DCU Operating Instructions 17
Device Description
3 Device Description
3.1 Device Overview
The device is designed for cultivating microorganisms and cells in discontinuous and
continuous processes.
It was designed for cultivating microorganisms and cells at various reactor volumes.
The device can be used to conduct studies on developing and optimizing fermentation
procedures and to perform limited-volume production fermentation processes in a
reproducible way.
The BIOSTAT
®B-DCU bioreactor can comprise the following basic units:
− 1 control unit with measurement and control system (DCU system)
− 1 to 6 supply units with connected culture vessel
123
Fig. 3-1: Sample BIOSTAT
®B-DCU with three connected supply units and culture vessels
No. Description
1 Control unit with measurement and control system (DCU system) and
operating display
2 Supply unit, in the example: with aeration system, 8 metering pumps,
and temperature control module for double-walled culture vessels
3 Culture vessel

18 BIOSTAT
®B-DCU Operating Instructions
Device Description
3.1.1 Control Unit
One to six supply units with different culture vessels can be connected to the control
unit.
The DCU system of the control unit controls and regulates the connected supply
units. The DCU system offers the following functions for each culture vessel
connected to a supply unit:
− Online measurement, online control, online analysis of process variables
(e.g., temperatures, pH, and DO values)
− Independent monitoring of process sequences
5 6 7
910
8
1
23
4
Fig. 3-2: Control unit overview

BIOSTAT
®B-DCU Operating Instructions 19
Device Description
No. Description Description
1 Operating display
2 USB USB port for peripheral devices
(with screwable cover)
3 Mains I/O Illuminated push-button
− Button: Switches the measurement and control system
(DCU system) on
− Display:
− Light on: Device is switched on
− Light off: Device is switched off
4 Potential equalization
5 Mains In Power supply/mains disconnector
6 Com Alarm Potential-free alarm contacts (X23)
When an alarm triggers (see Chapter 10.3, page 163):
− Contact open (break contact)
− Contact closed (make contact)
7 Host Ethernet port for an external host system
e.g., MFCS SCADA
8 Tower A ... F Connection of up to 6 supply units
Tower A ... F corresponds to supply unit 1 ... 6
9 Fieldbus Port for optional network-compatible components
10 Manufacturer’s
ID label

20 BIOSTAT
®B-DCU Operating Instructions
Device Description
3.1.2 Supply Unit
The supply unit provides power, gases, and supply media to the connected culture
vessel. It forms the interface between the culture vessel and the measurement and
control system (DCU system) of the control unit.
3.1.2.1 Front View (with/without Variable Area Flow Meter)
9
8
7
6
5
1
2
3
4
Fig. 3-3: Front view of supply unit
No. Description Description
1 Ready indicator Illuminates when the power supply is switched on
2 Mains I/O Main switch/mains disconnector
3 Rack − Cannot be used in conjunction with variable area
flow meters
− Rack for small parts
4 Connection panel
5 Motor support Stirrer drive holder
6 Up to 8 peristaltic pumps with rotary switch
7 Peristaltic pump rotary switch for filling/clearing
8 Variable area flow meter (optional)
Cannot be used in conjunction with rack
9 Aeration system (see Chapter 3.1.3, page 23)