Functions of the ADI 1060 Bio Controller:
• Control up to four bioreactor systems with one controller
• Easy to operate
• Superior data presentation
• Great flexibility
• Validatable
• Ultimate safety

The ADI 1060 Bio Controller can run up to four bioreactor systems. The I/O capabilities of the system are virtually unlimited, since the I/O system (with its own microprocessor) is located one-on-one with every bioreactor. This way the sensitive sensor signals are direct converted into less sensitive digital information leaving no risk for external disturbances. The I/O systems are connected to the ADI 1060 Bio Controller using one single cable.

The dedicated keyboard uses pictograms to show the functions that are available. In combination with the background color of the keys, this offers a very simple operation. No key combinations are needed because every key has one single function. Operator and engineer training can be limited to an absolute minimum. The keyboard it self is one molded silicone rubber pad that can be hosed down to be cleaned.

Data is presented in synoptics, line graphs, bar graphs and data tables. Each of these presentations has eight different displays. This means that there are eight synoptic displays, eight line graph displays, eight bar graph displays and data table displays.

The synoptic display shows a graphical presentation of the bioreactor system with the status of the valves, pumps and other actuators. Process values and process messages (alarms, process time, process name and so on) are displayed. Synoptic displays are designed to mimic exactly the bioreactor system that is controlled.

The line graph shows the proceeding of up to four process parameters per graph display. Data is stored up to 72 hours. Value and time axes are user adjustable. Line graph displays can be shown with a span of a half-hour up to 72 hours.

Bar graphs show a graphical presentation of the alarm values and the setpoint value versus the measured process value. Controller status and controller output values are shown in numeric presentation. Bar graph displays are used definable. The user can group logical parameters to be shown in one display.

Alarm values include yellow alarm (deviation alarm) which is a process warning and red alarm to indicate a serious problem. In case of sensor failure, a transmitter alarm is generated.

The actual measured data is stored for seventy-two hours. The table display allows the user to review the actual measurements over this past period. This is specifically useful when the supervisory system is in a different location (e.g. control room) or when working in a clean room where computers of the supervisory control system are preferably in a different (not clean-room) location.

The data available locally at the bioreactor allows the user the make decisions based on process proceedings without having to change out of their clean-room outfit to consult the supervisory system.

Other functions of the ADI 1060 Bio Controller are:
• Calibration of sensor inputs and analog I/O signals
• Starting and stopping of controlloops
• Dose-monitoring of pumps

Flexibility
The ADI 1060 Bio Controller allows the user (engineer) to define any controlloop based on sensor signals or analog input signals. These controlloops can use any of the analog and digital outputs. The number of outputs per controlloop is unlimited.

These definitions in combination with controller settings (setpoints, PID values, and controller status) are stored in the controller. Up to 99 process definitions are stored in the controller with user defined names. Replicating old experiments is very easy. Just reload the controller settings from memory and redo the process. The ADI 1060 Bio Controller prevents you from the tedious reprogramming of controllers. The ADI 1060 will remember what you did before and will redo this on your demand. This makes working with a control system a lot easier and prevents the occurrence of programming errors.

The process definitions stored in memory include:
• Synoptic displays
• Controller values
• Controller definition
• Bar graph definition
• Line graph definition
• Table definition

Using the recipe-programming feature of the ADI 1060 Bio Controller, the complete control system can be re-programmed from e.g. a bacterial set-up into a mammalian cell-culture set-up by just one single keystroke. Obviously features like recipe programming are password protected.

Since the system is used in pharmaceutical industry, validatability is of great importance. To be able to meet these demands the development documentation and software coding is at validation level. The ADI 1060 Bio Controller can be used in cGMP research and production.

The ADI 1040 Bio Interface

Capabilities
The ADI 1040 Bio Interface takes care of low level control near the bioreactor system.

This low-level control consists of:
• Calibration of input signals
• Calibration of output signals
• Alarm signal handling
• Controlling of outputs
• Conversion of input and output signals into serial information
• Controls the process at last received parameters

The ADI 1040 Bio Interface is a modular intelligent front-end process interface. The system has its own processor and it accommodates sensor cards and input/output (I/O) cards. Sensor cards receive information from sensors like pH, DO2, temperature, level. I/O cards receive information from analog inputs for stirrer speed controllers or mass-flow-controllers and digital inputs like valve- or switch position indicators.

Output cards send information to digital output cards to control valves, heaters, and pumps and to analog outputs for mass flow controllers and motor controllers. The ADI 1040 Bio Interface is located on the basic frame of the bioreactor to reduce the cabling between bioreactor and control system. All signals are digitized as soon as they enter the Bio Interface to ensure the accuracy of the measurements.

Communication between the ADI 1060 and ADI 1040 is serial using an RS 485 interface. This network communication interface allows long distance communication between the units (up to 1200 meters). The ADI 1060, which is the user interface, can be in a different location than the ADI 1040, which is the process interface. This set-up offers great flexibility in setting-up laboratories and plants.

Resuming
The ADI 1060 Bio Controller is a validatable control system capable of controlling up to four bioreactor systems. The multi processor design offers great flexibility in combination with ultimate safety; the ADI 1060 can be tuned exactly to the demands of every specific process. The combination of the dedicated keyboard with the full color 10" TFT display makes the system very easy to operate and offers a superior data presentation. No more searching for information, because everything is right there under your fingertips. Using the ADI 1060 for process control will result in better process results because more information is available locally to make the right decisions at the right time when working with the bioreactor system.