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XCell ATF Series, User Manual

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XCell ATF Series User Manual Download Page 44

 

 

 

 

 

 

40 

XCell

TM

 ATF System with C410:V3 Controller 

User Guide 

• Exhaust Set Point cannot be reached. E-Regulator (PV2) below minimum operating 

setting.  

The following is a list of C410:V3 controller Alarms that can occur during normal operation: 

• XCell

TM

 ATF System Warning has not been acknowledged. XCell

TM

 ATF System function 

halted.  

• Main Power Loss (120/220) while Diaphragm Pump was running.  

 

 

Summary of Contents for ATF Series

Page 1: ...XCellTM ATF System With C410 V3 Controller USER GUIDE XCell ATF4 XCell ATF6 XCell ATF10...

Page 2: ...in connection with the furnishing performance or use of this material No part of this document may be photocopied reproduced or translated to another language without the prior written consent of Rep...

Page 3: ...tration Assembly 18 5 2 Primary Pneumatic Services 19 5 3 Primary Electric Services 21 5 4 Signal 21 5 5 C410 V3 Ethernet set up and Connectivity 21 6 C410 V3 Controller Process and Control 22 6 1 Int...

Page 4: ...nce 57 10 1 Diaphragm 57 10 2 Pump Air Inlet Filter 57 10 3 O Rings gaskets and Quick Connects 57 10 4 Controller Maintenance 58 Appendix 1 XCellTM Cycle Time vs Flow Rate 59 Appendix 2 User Access 60...

Page 5: ...rocess vessel Bioreactor Adaptor adaptor between the Connection Assembly and bioreactor port Typical ports connectors adaptors for stainless steel bioreactors include an Ingold type port or if a singl...

Page 6: ...hrough the filtration device The second pump chamber the Pump Air PA chamber is connected to the pump flow control system Typically controlled addition of compressed air into the PA chamber increases...

Page 7: ...ng the process vessel at atmospheric pressure On the other hand when using a vessel that can be pressurized vessel pressure can be used to drive the liquid from the vessel to the PL chamber When vesse...

Page 8: ...s XCellTM ATF Pump Housing XCellTM Controller Description XCellTM ATF4 Stainless Steel C410 4V3 C410 V3 C410 controller for XCellTM ATF4 system with air tubing C410 4V3 GMP C410 V3 C410 controller for...

Page 9: ...XCellTM ATF System with C410 V3 Controller User Guide 1 4 XCellTM System Interconnectivity Drawing Figure 3 C410 V3 controller with XCellTM ATF10 stainless steel pump housing and pressure relief valv...

Page 10: ...5 psi 2 4bar Working regulated pressure VACUUM SERVICE 20 508 mm Hg at maximum flow use a service capable of sustaining 20 Hg at full flow EXHAUST Untreated discharge or user specified ELECTRICAL 100...

Page 11: ...t and effective area XCell ATF 4MC System 44 10 8x12 XCell ATF 6 System 44 10 8x12 XCell ATF 10lgcy System 44 14 14x20 XCell ATF 10 System 44 14 14x20 XCell ATF 6 Single use Device 38 12 10 XCell ATF...

Page 12: ...in Figure 3 Certain parts may vary depending on requirements and specifications Optional components for the XCell ATF housing include bioreactor connection kits pressure transducers vacuum pump and op...

Page 13: ...XCell 50A P C Silicone 1 8 0 295 C S x 6 835 ID x 7 425 Silicone 2 9 90 Degree Elbow 1 5TC 316 SS 1 10 Sanitary Gasket 1 1 2 TC EPDM 5 11 Clamp Sanitary 1 1 2 TC 304 SS 5 12 Sanitary Gasket 3 4 TC EPD...

Page 14: ...10 XCellTM ATF System with C410 V3 Controller User Guide Figure 4b Exploded View of XCell ATF 10 Single use Device with 0 2u PES Hollow Fiber Filter...

Page 15: ...11 XCellTM ATF System with C410 V3 Controller User Guide Table 4b XCell ATF 10 Single use Device Components...

Page 16: ...12 XCellTM ATF System with C410 V3 Controller User Guide Figure 4c Exploded View of XCell ATF 6 System Filtration Assembly P N ATF6 PH GMP...

Page 17: ...13 XCellTM ATF System with C410 V3 Controller User Guide Table 4c XCell ATF 6 Pump Housing Parts List...

Page 18: ...14 XCellTM ATF System with C410 V3 Controller User Guide Figure 4d Exploded View of XCell ATF 6 Single use Device with 0 2u PES Hollow Fiber Filter...

Page 19: ...413 O Ring Class VI 70A Silicone 2 12 233 O Ring Class VI 70A Silicone 2 13 Air Inlet Filter w 1 4 NPT male ends gamma stable 1 14 Poly Tube 1 4 ID x 3 8 OD White 1 15 GE ReadyMate to 1 TC 3 16 GE Re...

Page 20: ...16 XCellTM ATF System with C410 V3 Controller User Guide Figure 4e Exploded View of XCell ATF 4 System Filtration Assembly P N XCell ATF4 PH GMP...

Page 21: ...re 5 and the P Box Figure 4 The two are interconnected with a cable that relays signal and power A general layout of the two boxes with the XCellTM ATF System is shown in Fig 1 The primary design obje...

Page 22: ...Interconnect Cable Plug c Plugs for sensor inputs 4x4 20mA d Connection for Diaphragm Pump e Connection for compressed air f Connection for vacuum supply g Pressure regulator 0 to 60psi 0 to 4 1 bar h...

Page 23: ...neumatic Services Air inlet e Located on the P Box and provides an inlet to house compressed air source Recommended minimum air pressure requirement is 50psi 3 4bar Somewhat higher inlet pressures may...

Page 24: ...low of liquid from the Filtration Assembly to the P Box Air Pressure regulator Typical range of regulator is 0 60psi 4 1bar This is a second stage pressure regulator for regulating service air inlet p...

Page 25: ...is an open Industrial Ethernet standard developed by the PROFIBUS Organization and is standard Ethernet IEEE802 3 The Profinet communication protocol sends and receives data using the open Ethernet T...

Page 26: ...ed in Server Client pairs The OPC Server is a software application that bridges the communication of the PLC with the Windows environment and then with the OPC Client Software application Some common...

Page 27: ...n the Primary Screens Screen Description LOG ON Initial System Log On which appears when the C410 V3 controller first powers up MAIN Main Diaphragm Pump Control Monitoring Displays Real Time Pump Stat...

Page 28: ...User Guide Description of Screens and Buttons A LOGON Logon screen appears when the C410 V3 controller is powered up Click on LOGON to bring up User Password Dialog Box and Keyboard For first time us...

Page 29: ...starting the Diaphragm Pump a dialog box will appear to enable the user to start with current settings start with default settings or cancel and return to the main screen b When stopping the Diaphragm...

Page 30: ...e of last pump cycle Sec E FLOW SP Displays current E Flow Set Point SP LPM or Seconds E FLOW PV When running displays pump exhaust Flow rate Process Value PV of last pump cycle LPM E FLOW Calculated...

Page 31: ...Up Administration When starting the pump the following dialog box will appear Yes setting is preferred when stopping the Diaphragm Pump and restarting with the same flow rate or process settings i e...

Page 32: ...ance Set Up Screen Calibration Screen Help Guide Exit to Primary Screens Navigate to the following Secondary screens From the Basic Set Up Screen an Engineer Administrator can 1 Set initial Controller...

Page 33: ...m Set Point Sets a low limit on P2 pressure during the E Flow Cycle If P2is LOL follow with WARNING Alarm Delay msec Delays response to HIHI and LOLO Set Point If the alarm parameter is set for 0 minu...

Page 34: ...t enable this function unless you thoroughly understand its effects Button Description Advance Set Up Press to switch to Advanced Set Up Screen Help Guide Press to switch to Start up Help Guide Scree...

Page 35: ...limit for EFLOW set point LPM Min E FLOW sec Minimum limit for EFLOW set point Seconds PV1 Max Maximum operating limit for PV1 PV1 Min Minimum operating limit for PV1 PV2 Max Maximum operating limit...

Page 36: ...t Up Press to switch to Advanced Set Up Screen Calibration Instrument Calibration All Primary All Primary Screen Buttons are displayed to navigate to those screens Ethernet Configuration only accessib...

Page 37: ...personal or Repligen Field Service Engineer The Calibration screen will display parameters in the following tables Field Description Engineering Units Enter the Engineering Units for the selected anal...

Page 38: ...analog input Capture Second Calibration Point This button will capture the raw input value for the second point for the selected analog input Actual Value This button will finalize the two point calib...

Page 39: ...Controller User Guide The Trending screen displays an Overview screen from where the following trends are selected This screen monitors in real time the Flow and Exhaust Set Points and Process Values...

Page 40: ...mum value for the chart Y Axis Button Description Scrolls back to the beginning of the trend recording The start values with which the trend recording started are displayed Zooms into the displayed ti...

Page 41: ...Min Enter minimum value for the chart Y Axis Button Description Scrolls back to the beginning of the trend recording The start values with which the trend recording started are displayed Zooms into th...

Page 42: ...the Diaphragm Pump While the PLC records the output from the load cell in milliseconds the computer HMI is much slower and refresh rate is about once every 0 5 1 0 second therefore while one may not...

Page 43: ...ON POWER ON RUNNING C ON ON POWER ON WARNING D ON OFF Two 2 Pump Interlock Relays are provided which energize per the following states HARVEST PUMP STATE RELAY 3 RELAY 4 ACTIVE ON ON NOT ACTIVE OFF O...

Page 44: ...hed E Regulator PV2 below minimum operating setting The following is a list of C410 V3 controller Alarms that can occur during normal operation XCellTM ATF System Warning has not been acknowledged XCe...

Page 45: ...istrator User ID and 1 predefined Engineer Level and 1 predefined Operator Level User ID s Only the administrator will have security access to add edit delete all other User ID s by touching the appro...

Page 46: ...MIN Basic Screens Each level of security allows different levels of access to the C410 V3 controller control functionality please refer to Appendix 2 for details Note Software version numbers shown ab...

Page 47: ...psed time of current batch run Time is reset by changing Batch Name Cycle Count Displays Diaphragm Pump Cycle count of current batch run User ID Displays Users ID Engineer or Administrator Batch Set U...

Page 48: ...y parameters in the following tables Field Description Algorithm Performance Tracks cycle change mechanism Primary Method Shows cycle count triggered by Set point method tracks Pressure cycle and Exha...

Page 49: ...calculate the Diaphragm Pump cycle time based on a user s flow rate selection according to the following relationship The pump displacement volumes with no pressure difference across the diaphragm ar...

Page 50: ...rifice opening in combination with fine adjustments in the air flow stream pressure with the PRV Adjustments in flow are based on the error difference between Calculated CT and Actual CT The proportio...

Page 51: ...psi LoLo Alarm Set Point 7 psi Alarm Delay x10 msec 50 for both Pump Parameters VALUE P Pressure Offset psi 0 5 E Pressure Offset psi 0 5 P Delay 70 E Delay 70 P Overtime 120 E Overtime 120 P PV Step...

Page 52: ...essure Offset and P between PRV2 P2 should be less than E Pressure Offset If not manually lower PV in small increments b Flow is too rapid A flow that is too rapid during the Exhaust Cycle can be read...

Page 53: ...t connect the Pump Line from the C410 V3 controller to the Diaphragm Pump at this point 6 Power ON the E Box Wait for system to boot up and display the XCellTM ATF System LOGON screen 7 LOGON the main...

Page 54: ...placing a HFM in Filtration Assembly connected to a pressure rated vessel Prerequisites Steam is available and the HFM has to be replaced in mid run in a sterile manner Refer to Figure 1 7 1 Separatin...

Page 55: ...odule Preparation Instructions that are included with every hollow fiber There are different preparation methods depending on the module type purchased Two types of HFMs are available for the XCellTM...

Page 56: ...nto the housing 3 Insert one O ring into the groove formed between HFM and Filter Housing end ferrule wall 4 Place the reducer onto the end forcing the O ring into the groove 5 Clamp the reducer to th...

Page 57: ...here 2 Clamp the two hemispheres with the C clamps use the three long clamps first and place 120 degrees to each other about the Diaphragm Pump periphery 3 Uniformly and sequentially tighten the clamp...

Page 58: ...ully assemble Filtration Assembly as shown in Figure 9 8 1 3 Perform a pressure test 8 1 4 Vent all ports blocked with 0 2micron vent filters With both the filtrate and retentate sides vented formatio...

Page 59: ...n autoclave The XCellTM ATF System Filter Preparation and Autoclave Guide provides detailed guidance on the entire procedure including the recommended filter integrity test procedures and specificatio...

Page 60: ...5 60 min Ramp down slowly with wet cycle exhaust protocol or 0 5 10 C min to 1000 C Allow the system to cool to 50 oC before handling 8 2 3 Open autoclave door inspect the system re tighten all clamps...

Page 61: ...the Steam inlet valve and immediately open the main valve into the Filtration Assembly to minimize a pressure drop in the connection Note that following SIP of the connection the cool down of the conn...

Page 62: ...P box 6 Inspection of pneumatic fittings 7 Inspection of the pneumatic tube from the P box to the XCell ATF pump housing 8 Inspection of enclosure for damage locks and hinge performance external elect...

Page 63: ...ystem PUMP VOLUME L ATF4 0 4 ATF6 1 3 ATF8 2 5 ATF10 lgcy 5 1 ATF10 6 0 Cycle time sec FLOW RATE L MIN 4 6 0 18 8 37 5 76 5 90 0 6 4 0 12 5 25 0 51 0 60 0 8 3 0 9 4 18 8 38 3 45 0 10 2 4 7 5 15 0 30 6...

Page 64: ...ending PV1 Input Value Not Allowed PRV1 Input Value Not Allowed PV2 Input Value Not Allowed PRV2 Input Value Not Allowed P2 General View Only Alarms View Only General Allowed Silence Alarm General Not...

Page 65: ...General Access View Not Allowed no access to Set Up Screens Admin Basic General Access Not Allowed Users General Access Not Allowed Engineer Main Screen General Access General Access Upon Login Start...

Page 66: ...d to adjust Min and Max P4 Trend General View and allowed to adjust Min and Max P5 Trend General View and allowed to adjust Min and Max WI Trend General View and allowed to adjust Min and Max Batch In...

Page 67: ...pressure and exhaust cycle fields PV Step Size Allowed to adjust pressure and exhaust cycle fields Alarm Set Points P2 Pressure Allowed to adjust HiHi and LoLo Fields Alarm Delay Allowed to adjust Hi...

Page 68: ...lowed Default Gateway Not Allowed Remote TSAP Not Allowed Calibration 1 General Access General Allowed Analog Input P2 Select Allowed Eng Units Not Allowed 1st Point Not Allowed Eng Units Not Allowed...

Page 69: ...h Point Not Allowed Eng Units Not Allowed 6th Point Not Allowed Actual Value Not Allowed Accept Allowed No changes occur Analog Input P5 Select Allowed Eng Units Not Allowed 6th Point Not Allowed Eng...

Page 70: ...iew Only P2 Trend Enable View only change range in trending Alarms View Only General Allowed Silence Alarm General Allowed Clear Alarm General Allowed Trending Overview General View and allowed to adj...

Page 71: ...ed Set Up Basic Controller Setup Pump Model Allowed to adjust Control Mode Allowed to adjust Alarm Delay Allowed to adjust Slope Function Enabled Allowed to adjust Bioreactor Pressure Allowed to adjus...

Page 72: ...Max Allowed to Adjust LPM and Seconds field Exhaust Cycle Flow Min Allowed to Adjust LPM and Seconds field Accept Changes Allowed Discard Changes Allowed Admin Set Up Advanced Output CV Limits PV1 Al...

Page 73: ...owed Analog Input PRV1 Select Allowed Eng Units Allowed 2nd Point Allowed Eng Units Allowed 3rd Point Allowed Actual Value View Only Accept Allowed Analog Input PRV2 Select Allowed Eng Units Allowed 3...

Page 74: ...t W1 Select Allowed Eng Units Allowed 7th Point Allowed Eng Units Allowed 8th Point Allowed Actual Value View Only Accept Allowed Help General Access View only Allowed Admin Basic General Access Gener...

Page 75: ...XCellTM ATF4 ATF6 and ATF10 pump falls under the article 3 3 of the Pressure Equipment Directive 97 23 EC and indicate the pumps are compliant with the SEP Sound Engineering Practice For XCellTM ATF p...

Page 76: ...Controller software v3 has been marked legibly and indelibly with the following information Name and address of the manufacturer Rated voltage full load amperage and frequency Serial number Short circ...

Page 77: ...lter between the XCellTM ATF System and the Controller o Inspect air and vacuum connections to the controller o Inspect that all components inside of the controller are secured and intact o Inspect en...

Page 78: ...ordance with the ASME Boiler and Pressure Vessel Code XCell ATF Single use devices are designed and validated to withstand a pressure of 60 PSIG at 40 oC All device units are subjected to a pressure h...

Page 79: ...and the device fields populate with the current configuration h From this interface the IP Address Subnet Mask and all other Ethernet Properties can be adjusted i Once the values have been entered sel...

Page 80: ...Real 66 DB1 DBD66 Min Exhaust Flow Setpoint LPM PTIME Real 70 DB1 DBD70 Pressure Flow SEC PTIMESP Real 74 DB1 DBD74 Pressure Flow Setpoint SEC PTIMEMAXSP Real 78 DB1 DBD78 Max Pressure Flow Setpoint...

Page 81: ...eal 574 DB1 DBD574 PRV2 Process Value P3_PV Real 582 DB1 DBD582 P3 Process Value P4_PV Real 586 DB1 DBD586 P4 Process Value P5_PV Real 590 DB1 DBD590 P5 Process Value W1_PV Real 594 DB1 DBD594 W1 Proc...

Page 82: ...N A N A N A Spare N A N A N A N A N A N A Spare N A N A N A N A N A N A PL1 System Stop Indicator Q0 0 N A N A N A N A N A HN1 System Fault Warning Horn Q0 1 N A N A N A N A N A SOL1 Pump Inflate Def...

Page 83: ..._1 Optional Pressure 4 IW106 Note 1 N A PSI N A Y RAW_P5_PV_1 Optional Pressure 5 IW108 Note 1 N A PSI N A Y RAW_W1_PV_1 Optional Weight IW110 Note 1 N A LBS N A Y RAW_PRV1_CV_ Inflation Pressure QW12...

Page 84: ...stem Fault Warning Horn DB1 WARN_REG 0 Flow Set Point cannot be reached Air Supply Regulator PRV1 above maximum pressure setting DB1 DBX132 0 Pump is Running PRV1 PRV1 MAX N A Warning Activate System...

Page 85: ...200 C2410 E AX CPU SIMATIC S7 200 CPU module XCell ATF 6 Pneumatics Spares C410 P6 RF PM Pressure Manifold for C410 6 C410 P6 RF EM Exhaust Manifold for C410 6 C410v2 P48 RF SOL1 ASSEMBLY 3 way valve...

Page 86: ...Barb Fitting XCell ATF6 AIR ASSY Air Inlet Assembly XCell ATF6 P3 CPM1 5 TC3 4 Kit PT 1 5 CPM Fitting 3 4 TC XCell ATF6 PH AA AIR Air Hemisphere XCell ATF6 w XCell ATF6 AIR ASSY XCell ATF 10 Pump Hous...

Page 87: ...TS Thumb Screw for XCell ATF10 XCell ATF8 Base XCell ATF10 AIR ASSY Air Inlet Assembly XCell ATF10 XCell ATF10 PH AA AIR Air Hemisphere XCell ATF10 w XCell ATF10 AIR ASSY P3 CPM1 5 TC3 4 Kit PT 1 5 CP...

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