Applikon ADI 1075 - User Manual

The Applikon ADI 1075 Pilot System is an actuator console designed for bioprocess control, specifically for use with In Situ Sterilizable ADI bioreactors and an ADI 1060 or ADI 1030 Bio Controller. It supports various control functions including gas flow regulation, head plate lift control (optional), stirrer speed control, level control, temperature control, and liquid addition with pumps. The system is available in two frame versions, one for 20-70L bioreactors and another for 100-300L bioreactors.

Function Description:

The ADI 1075 Pilot System acts as the primary interface for controlling and monitoring various aspects of a bioprocess. It integrates multiple control sections into a single console, allowing for comprehensive management of the bioreactor environment.

General:

The system is designed as an actuator console for bioprocess control and should not be used for other purposes. It is a Safety Class I apparatus, designed in accordance with IEC1010-1 "Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use." It has been supplied in a safe condition, and users must follow the installation manual's information and warnings to ensure safe operation.

Gas Supply Unit:

The gas supply unit supports four rotameter assemblies and/or mass flow controllers for nitrogen, air, oxygen, and carbon dioxide. These gasses are internally connected to a manifold where they are mixed and directed to the gas supply bulkhead connector at the front of the Pilot System. Rotameter assemblies can be applied with or without a Valve Module. The valve module contains a non-return valve to prevent backflow into the supply system.

Lift Control (Optional):

For systems with electrical head plate lifting, the lift control section includes a key switch and two LED indicators (Enabled, Active). The actuator for lifting can be electric or electric/hydraulic. The head plate lifting device is considered a machine with potential hazard due to moving parts and must comply with European Community legislation on machinery. During normal operation, the key must be removed from the lift control section and kept in a secure place, with operation restricted to authorized personnel. Before lifting or lowering the head plate, ensure the pressure inside the reactor equals environmental pressure and all head plate bolts are released/removed.

Temperature Control:

The temperature control section includes indicators for sterilization, cooling, fermentation, and heating, along with an illumination push button and a tumbler switch (for ADI 1030 Bio Controller). The wet part of the system, which includes a heater, circulation pump, pneumatic valves, and piping, is connected to the bioreactor for temperature regulation. During sterilization, the wet part is filled with steam and then cooled. During fermentation, recirculation and heating are enabled, with cooling water introduced if the temperature exceeds the set point.

Stirrer Speed Control:

The ADI 1075 Bio Console can be equipped with four different stirrer speed controllers for various stirrer motors. The stirrer speed control section features a power/overload indication, a display for stirrer speed (rpm), a power on/off switch, a local/remote switch, and a potentiometer for manual speed adjustment. The stirrer motor is also considered a machine with potential hazard under European Community legislation, requiring adherence to safety instructions, fuse rating, and functionality outlined in the stirrer speed controller user manual.

Level Control:

The Level Control option activates a pump upon liquid contact with a level sensor, used for both foam and level control. The level control section includes a level sensor connection, an on/off/auto switch, and an LED indicator for pump 3 activity. In "on" mode, pump 3 runs continuously; in "off" mode, it stops; in "auto" mode, it activates when liquid contact is detected.

Pumps:

The Pump Section provides four positions for fixed-speed pump drives. Each pump position has an on/off/remote switch. "On" means continuous operation, "off" means the pump is switched off, and "remote" means the pump is activated by a digital output signal from the control device. Pump 3 is typically used for level control if the level control module is installed. Pump drives are considered machines with potential hazards and must only be used with specified pump heads and tubing.

Important Technical Specifications:

• Mains Supply: 400V3~ or 200V3~ High Voltage Current. Available in 115 Vac and 230 Vac voltage selection packages. Minimum specification of the mains cable is 5 x 2.5 mm². An external mains supply switch (4 poles, 25 A) is required.
• Water and Steam Supply:
  • Water pressure: 1.5 - 3.5 barg
  • Steam pressure: 2.0 - 2.5 barg
  • Max. Steam temperature: 140 °C
  • Piping diameter: 12.7mm OD (for 20-70L bioreactors) or 21.3mm OD (for 100-300L bioreactors).
• Compressed Air & Gas Connections:
  • Tube diameter (OD) for compressed air: 6 mm
  • Tube diameter (OD) for other gasses: 8 mm
  • Required air pressure for actuators: 6 barg
  • Required pressure for MFC and rotameter applications: 2 barg
• Fuses: Various fuses are located behind the rear panel and on the internal power supply board. All fuses must comply with IEC 127.
  • Main Fuses (F1-F3): Ceramic Bus Type, 20A (110/120Vac), 10A (230Vac).
  • Power-On (F4): 5x20mm, T1A (110/120Vac), T0.5A (230Vac).
  • Unswitched Power Supply (F5): 5x20mm, T2A (110/120Vac), T1A (230Vac).
  • Switched Power Supply (F6): 5x20mm, T1.6A (110/120Vac), T0.8A (230Vac).
  • Lifting Device / Level Sensor Circuit (F7): 5x20mm, T1.6A (230Vac) for lift control, T2A (110/120Vac), T1A (230Vac) for level.
  • Heating Circuits (F11-F13): 5x20mm, T10A (110/120Vac), T5A (230Vac).
  • Thermal Cut-off (F31): 5x20mm, T0.5A (24Vdc).
  • Internal Power Supply Board Fuses: F1 (Main Fuse: T5A 110/120Vac, T2.5A 230Vac), F2 (24Vdc: T6.3A), F3 (12Vac: T2A), F4 (230Vac: T1A).
• Environmental Conditions:
  • Indoor use
  • Altitude: up to 2000 m
  • Temperature: 4°C to 45°C
  • Maximum relative humidity: 80% up to 31°C, decreasing linearly to 50% at 45°C
  • Transient over voltages: INSTALLATION CATEGORIES II
  • Pollution Degree: 2 (IEC 664)
  • P-max: 6900 VA

Usage Features:

• Modular Design: The system is designed with various control sections (gas supply, lift, temperature, stirrer, level, pumps) that can be configured based on specific bioprocess needs.
• Emergency Stop: An Emergency Stop button switches off all actuators while maintaining power to I/O hardware and control devices, allowing continued measurement of process parameters. Resetting requires turning the key clockwise.
• Power-On Sequence: Before switching on main power, ensure the wet part and reactor jacket are filled with water to prevent damage to the circulator pump.
• Illumination: An optional illumination assembly in the bioreactor head plate can be activated via a push button for approximately 1 minute.
• Stirrer Control Modes: "Local" mode allows manual stirrer speed adjustment via a potentiometer, while "Remote" mode enables control by the ADI 1010 Bio Controller.
• Pump Control Modes: Pumps can be set to "on" (continuous), "off," or "remote" (activated by a digital output signal from the control device).
• Level Control Modes: The level control pump can be set to "on" (continuous), "off," or "auto" (activates when liquid contact is detected).

Maintenance Features:

• Fuse Replacement: Fuses are located behind the rear panel and on the internal power supply board. The rear panel can be removed by turning pawl latches counter-clockwise, but the earth wire must be disconnected first. Only fuses with the required rated current and specified type (IEC 127) should be used.
• Water and Steam Supply Valves: Manually operated ball valves should be installed in both steam and water supply lines to cut off supply during service and maintenance. These valves must be clearly marked.
• Gas/Air Supply Valves: Manually operated valves are required in all gas/air supply lines to cut off supply during service and maintenance, and must be clearly marked.
• Cleaning: The ADI 1075 Pilot System cabinet and frame can be cleaned with a moist tissue and a non-abrasive cleaner.
• Pump Head and Tubing Replacement: Power to the pump drive must be switched off before replacing tubes or pump heads. Regular verification of tube quality inside the pump head is recommended before each fermentation run.
• Heater Thermal Cut-off: The heater has an adjustable thermal cut-off, which should be adjusted to approximately 60°C to prevent local hot spots in the reactor.