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General
The Novaferm Fermenter Control System is a microprocessor control
system for direct digital control of fermentation processes based on
programmable logical controllers (PLC) from the SIMATIC S7 (Siemens)
family. The modular concept allows control of fermenter systems from
laboratory to industry scale. The system operates as a powerful stand
alone control system, for the basic fermenter controls, including
sequence control, PID control, cascade controls etc.
The operator interface (HMI) is based on a standard Pentium PC
with special operator software (PC Operator Program) operating under WNT/W2K/WXP.
The Novaferm Fermenter Control System supports communication with
external systems via PROFIBUS.
The control system is available in table top or panel mounted
executions.
Operator Unit
The operator interface (HMI) consists of a Pentium or Pentium-Pro
PC loaded with the Operator Program. The PC is connected to the control
system via a serial interface RS232.
The operator program is running under Windows WNT/W2K/WXP and
consists of menus that the operator controls from a key board, mouse or
by other tracking tool. All necessary functions in the PLC unit can be
reached from the screen and complete programming of the process can be
done.
Process data can be logged to file and printer. Logged data can be
processed in e.g. Microsoft Excel.
The process definition can be saved to file for future use.
The operator program gives the possibility for graphic
presentation of real time data from all analog inputs.
Alarms are indicated acoustically and visually on the screen and
information about time and event is indicated.
To facilitate operation of the program all menus have a
instructive help page.
I/O Unit
The I/O unit is mounted on a 19" profile and contained in separate
cabinet (table top) or mounted directly in the instrument part of the
piping cabinet. The unit consist of a power module (24 VDC) a CPU unit,
digital output module(s) , analog input module(s) and a communication
module. As an option the unit can be equipped with interface for
communication with other Novaferm Fermenter Control Systems via PROFIBUS
.
I/O Modules
The I/O modules comprise analog signal modules in combination with
special signal transmitters for sensors in fermentation processes (see below)
and digital outputs with relay function for operation of actuators like
contactors, solenoid valves and pumps.
The following analog modules and transmitters are available:
- Temperature measurement (standard)
- Agitator speed measurement (standard)
- Gas flow measurement (option)
- pH measurement (standard)
- pO2 measurement (standard)
- Foam indication (standard)
- Pressure measurement (option)
- Redox measurement (option)
- Agitator current measurement (standard)
- Level (load) measurement (option)
- General input measurement (option)
The general input measurement can be used e.g. for signals from
instruments measuring O2 and CO2 in exit gas,
turbidity and glucose.
The digital output modules can be delivered in different
executions. As a standard the system has 16 digital outputs with
switching AC operating voltage up to 220 V, 2A. The outputs are
controlled by the program, but can also be manually actuated by the
operator from the MMI.
Specification
The standard system consists of the following modules:
- Power module
- CPU
- Module with 16 digital outputs
- Module with 16 digital inputs
- Module with 8 analog inputs
- Module with 4 analog outputs
- Communication module
- Transmitters for pH and pO2
- Module for foam
- Software for fermentation control (including sequence program
and PID control)
- Software for operator unit (PC Operator Program)
All sensors and cables to the control actuators are normally
included in the system.
The system allows the user to build process sequences with up to 12
phases, each with individual subroutines for Heating, Sterilisation,
Cooling, Fermentation, Emptying etc.
Additional to the controllers the digital outputs can be actuated
by limit values that can be set in each phase. Alarms and timers can also
be trigged by limit values.
Step to next phase in the sequence can either be made
automatically by user selected step conditions or manually.
The sensors can be individually calibrated, automatically using
reference values and two point calibration, or, if the characteristics of
the sensor are known, the calibration values can be entered manually. The
measured value of e.g. pH can be temperature compensated by entering a
compensation constant.
Printing of the measured values, including current settings of
digital outputs, can be done. Selection of printing interval in each
phase of the process is done in the definition menu.
Setpoint and other control parameters can be changed during run
without interrupting the program execution.
A battery back up retains the process parameters in RAM to ensure
smooth restart after a power failure.
Supervision of the process from any computer in local network can
be done by using an optional program module (PC Viewer Program).
Recommended PC-hardware for the Operator Unit
(not part of standard delivery)
- A personal computer (PC) with a Pentium (or compatible)
processor
- A minimum of 128 Mb of memory for WNT/W2K/WXP
- At least 1 GB of free hard disk space
- A Windows compatible industrial standard keyboard
- A Windows compatible mouse
- A Windows-supported graphics adapter card (SuperVGA.)
- A PC-compatible colour monitor
- A Serial port for communication with the control system
- Windows compatible printer (network/local)
Required PC-software for the Operator Unit
- Microsoft WNT/W2K/WXP operating system
- PC Operator Program for WNT/W2K/WXP
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