XCell
TM
ATF System
With C410:V4B Controller
USER GUIDE
XCell™ATF4 | XCell™ATF6 | XCell™ ATF10
XCellTM ATF System with C410:V4B Controller User Guide
The information contained in this document is subject to change without notice.
Copyright © 2019 Repligen Corporation (XCell™ ATF technology acquired by Repligen in
June, 2014)
Repligen Corporation makes no warranty of any kind with regard to this material, including, but
not limited to, the implied warranties of merchantability and fitness for a particular purpose.
Repligen Corporation shall not be liable for errors contained herein or for incidental or
consequential damages 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 Repligen Corporation.
For further information, please contact Repligen Corporation.
www.repligen.com
Revision History
XCell™ ATF System with C410 Controller, Version v4B Release 2
C410v4B User Guide
Document Revision 2
XCellTM ATF System with C410:V4B Controller User Guide
Contents
1.0 Description of the XCell™ ATF (Alternating Tangential Flow) System and Process .................. 1
1.1 XCellTM ATF System Pump Cycle .................................................................................... 3
1.2 XCell™ ATF System Control Scope and Objectives ........................................................ 5
2.0 Utility Requirements ............................................................................................................. 5
3.0 Dimensions and Weight ........................................................................................................ 6
4.0 XCell™ ATF Pump Housing Assemblies ................................................................................... 7
See Appendix 7 for list of spares and accessories ........................................................................ 12
5.0 XCellTM C410v4B Controller Layout ...................................................................................... 17
5.1 General Layout ............................................................................................................. 17
5.2 Filtration Assembly (Stainless Steel) ............................................................................ 18
5.3 Pneumatics Box (P-Box) Components ......................................................................... 18
5.4 Electrical Box (E-Box) ................................................................................................... 18
5.5 Power Box (Power Separation) Components .............................................................. 20
5.6 Primary Pneumatic Services......................................................................................... 20
5.7 Primary Electric Services .............................................................................................. 21
5.8 Signal ............................................................................................................................ 21
6.0 C410v4B Controller Process and Control .............................................................................. 22
6.1 Control Overview ......................................................................................................... 22
6.2 Control Functional Algorithms ..................................................................................... 24
6.3 Interface and Screens .................................................................................................. 25
6.4 Startup ......................................................................................................................... 50
6.5 Examples ...................................................................................................................... 52
7.0 XCell™ ATF Hollow Fiber Module and Diaphragm Replacement............................................ 54
7.1 Separating the Filtration Assembly from the bioreactor ............................................. 54
7.2 HFM removal................................................................................................................ 54
7.3 HFM insertion .............................................................................................................. 55
7.4 Screen Module replacement ....................................................................................... 56
7.5 Diaphragm replacement .............................................................................................. 56
7.6 Assembly ...................................................................................................................... 57
7.7 Use ............................................................................................................................... 57
8.0 Sterilization ........................................................................................................................ 58
8.1 Preparation of Filtration Assembly for Autoclaving .................................................... 58
8.2 Autoclave Cycle ............................................................................................................ 59
XCellTM ATF System with C410:V4B Controller User Guide
8.3 Sterilization of Filtrate / Harvest line ........................................................................... 60
9.0 Connection to Bioreactor (ATF-to-Bioreactor) ...................................................................... 61
9.1 Hard Connection .......................................................................................................... 61
10.0 Maintenance ...................................................................................................................... 62
10.1 Diaphragm .................................................................................................................... 62
10.2 Pump Air Inlet Filter ..................................................................................................... 62
10.3 “O” Rings, gaskets and Quick Connects ....................................................................... 62
Appendix 1: Cycle time vs. Flow rate .......................................................................................... 63
Appendix 2: Access levels to the C410v4B controller ................................................................... 64
Appendix 3: Controller Lists: Alarm, Warning, Inputs & Outputs ................................................. 71
Appendix 4: Profinet Communication ......................................................................................... 73
Appendix 5: Profibus Communication ......................................................................................... 75
Appendix 6: Delta V Example configuration ................................................................................ 96
Appendix 7: OPC Communication ............................................................................................. 103
Appendix 8: Audit Trail (If Equipped) ........................................................................................ 113
Appendix 9: EU Declaration of Conformity ................................................................................ 116
Appendix 10: UL Listing ............................................................................................................ 119
Appendix 11: Spares List .......................................................................................................... 120
XCellTM ATF System with C410:V4B Controller User Guide
1
1.0 Description of the XCell™ ATF (Alternating Tangential Flow) System
and Process
The XCell™ ATF System provides an efficient means for fractionation of various mixtures. It may
include the separation of mammalian Cells (~ 10 microns in size) from culture medium, the
separation of large particles such as micro carriers (~ 200 microns in size) from a suspension
medium, or separation of some molecules from other molecules in a suspension. The user guide
details the use of the XCell™ ATF System, with the C410v4B Controller for the separation of such
components using hollow fiber filtration.
The system is designed to improve the efficiency of cell culture processing by allowing for the
generation of high viable cell densities. The system can enable continuous processing and is
available in stainless steel and single-use formats. Two primary components, the C410v4B
controller and the ATF pump housing, which in comprised of a diaphragm pump, filter housing
and a hollow fiber filter, are used for desired operation. The controller functions to control the
ATF (Alternating Tangential Flow) action by controlling the movement of the diaphragm pump,
through control of pressurization and exhaust (vacuum) to allow the up and down motion of the
diaphragm in the pump housing. This action displaces a known volume of cell culture material
within the retentate side of the hollow fibers. A separate pump continuously removes cell-free
permeate from the system. Primary components of the current controller include a PLC
(Programmable Logic Controller) with a HMI (Human Machine Interface) to control the
components used in generating the alternating tangential flow action.
This User Guide pertains to both the Stainless Steel Filtration Assemblies and the XCell™ ATF
Single-use devices, meaning that the C410v4B Controller information relates to the operation of
both the stainless steel and single-use ATF devices. (Figure 1).
• Controller: a dedicated controller used to control and monitor XCell ATF System activity. It
also provides the means for connecting to and controlling pressure and vacuum utilities.
• Filtration Assembly: an assembly of two major elements, a stainless steel filter housing and
a silicone diaphragm pump:
- Filter Housing: housing containing the filtration element, either a hollow fiber module (HFM) or
screen module (SM).
- Diaphragm Pump: spherical housing in which a diaphragm membrane is moved up and down by
pressurized air or vacuum, creating alternating flow.
- Single-use Device: the filter housing, hollow fiber filter and diaphragm pump are combined into
a single polycarbonate device. At this point in time the SM is not available as a single-use device.
Please see the XCell™ ATF Start-Up Guide for additional information on the single-use devcies.
The Filtration Assembly includes the following components for each process application:
- A2B Connection Assembly: tubing assembly connecting the Filtration Assembly to a bioreactor or
process vessel
- Bioreactor Adaptor: adaptor between the Connection Assembly and bioreactor port. Typical
ports/connectors/adaptors for stainless steel bioreactors include an Ingold-type port, triclamp
or, if a single use bioreactor (SUB), then, a disposable aseptic connector (DAC) or equivalent.
XCellTM ATF System with C410:V4B Controller User Guide
2
A typical configuration of the XCell™ ATF System is shown in Figure 1. The Filter Housing accepts
either HFM, with pore sizes from 750kD to ~0.2 micron, or a SM for fractionation of larger
particles, >70 microns. The separating element, the HFM or SM, is positioned between a process
vessel or a bioreactor at one end and the Diaphragm Pump at the other end. The vessel serves as
a storage container for the content to be filtered. The Diaphragm Pump provides the means for
generating alternating tangential flow (ATF), moving the contents of the vessel back and forth,
between the vessel and pump, through the hollow fibers of the HFM or through the SM. The
XCell™ ATF process provides the means for generating rapid, low shear, tangential flow, allowing
for retention of the larger components (i.e.- cells) and filtration of smaller components (i.e. –
media components).
A filtrate pump as shown in Figure 1 is used for controlled removal of a filtered stream. The
unfiltered material remains in the system. Only a single connection is required between the
XCell™ ATF System and the vessel. As shown in Figure 1, the connection can be through a side
port (or bottom port) commonly configured on large scale stainless steel or single-use
bioreactors, or through the head plate as typical with smaller bioreactors. When placed next to
the vessel, only a short connection, commonly referred to as the A2B Connection, is required
between the XCell™ ATF system and the vessel. This connection can be hard piped or soft piped
and is made in a sterile manner. The filtration process remains closed and therefore sterility
between the vessel and the XCell™ ATF System is maintained.
Figure 1. Filtration Assembly Connection to C410v4B Controller and a Bioreactor Side Port
Note: The XCell™ ATF C410v4B Controller has one additional enclosure, the power box (P-box)
which houses the high voltage electrical components (not displayed here). Please reference the
XCell™ ATF Single-use Start up Guide for proper single-use connectivity.
XCellTM ATF System with C410:V4B Controller User Guide
3
1.1 XCellTM ATF System Pump Cycle
The Diaphragm Pump is the heart of the XCell™ ATF System process. It produces an
alternating flow through the HFM (lumen side) or SM. The XCell™ ATF System provides a
pulsating, reversible, flow of liquid, back and forth, between the process vessel and the
Diaphragm Pump. The following is a description of that process:
The Diaphragm Pump is partitioned into two chambers with a flexible diaphragm, Figure
2. One of the pump chambers, the Pump Liquid (PL) chamber is connected to the Filter
Housing, which, in turn, is connected to the process vessel. Therefore, any flow between
the Diaphragm Pump and process vessel will be through 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
the pressure in the chamber relative to the process vessel, forcing the flexible diaphragm
partitioning the two chambers to move into the PL chamber and towards the vessel.
Liquid in the PL chamber is forced through the filter to the process vessel. The flow
through the HFM (lumen side) generates tangential flow in one direction. This pumping
phase (or cycle) in the direction of the bioreactor is called the Pressure Cycle. Inversely,
with a pressurized process vessel relative to PA or PL, or with an external vacuum supply,
liquid will flow in the reverse direction, from process vessel, through the HFM (lumen
side), to the PL chamber, generating tangential flow in the other direction. This pumping
phase (or cycle) in the direction of the XCell™ ATF pump is called the Exhaust Cycle. These
alternating pump cycles are then repeated continuously. See Figure 2.
Figure 2. XCell™ ATF System Pump Cycles
XCellTM ATF System with C410:V4B Controller User Guide
4
Note on the Exhaust Cycle:
WARNING
Glass bioreactors or single-use bioreactors (SUBs), unless otherwise specified by the
manufacturer of the vessel, should not be pressurized. Such vessels can explode if
pressurized.
If a vessel is being operated without positive pressure the XCell™ ATF requires a vacuum
(negative pressure) to move the diaphragm to its lowest position. The PA chamber can then be
alternately pressurized and evacuated to produce XCell™ ATF action while maintaining the
process vessel at atmospheric pressure.
Conversely, when using a vessel that that is operated under positive pressure, the vessel pressure
can be used to drive the liquid from the vessel to the PL chamber. When vessel pressure is
limited, it may be supplemented with vacuum. In either of the above schemes, one is driving the
liquid from the vessel to the Diaphragm Pump by increasing the pressure in the vessel relative to
the Diaphragm Pump. Even with positive vessel pressure assisting with diaphragm deflation,
vacuum is generally required to ensure proper ATF operation
WARNING
When using a glass vessel or SUB, be sure to maintain an unrestricted vent from the
vessel. In the case a diaphragm fails, the air flow into the Diaphragm Pump will proceed
through the HFM or SM into the vessel. A free exhaust from the vessel will minimize the
buildup of pressure in the vessel.
XCellTM ATF System with C410:V4B Controller User Guide
5
1.2 XCell™ ATF System Control Scope and Objectives
The C410 v4 Controller provides the process control functionality of the stainless steel
XCell™ ATF 4 System, XCell™ ATF 6 System, XCell™ ATF 10 System and the XCell™ ATF 6
and 10 Single-use devices. The XCell™ ATF C410v4B controller is designed to:
1. Control ATF flow rates in both pressure and exhaust cycles
2. Provide a user interface capability for XCell™ ATF System control and monitoring
3. Set-up and select operational parameters
4. Display real-time process data and Alarms for error conditions
5. Provide “Batch control” and user hierarchy
6. Have PLC software upgrades in the field by replacing memory modules
7. Have 3 major enclosures, an Electronics Box (E-Box) a Pneumatics Box (P-Box) and a
Power Box
8. Allow the E-Box to operate an XCell™ ATF 4, 6 and 10 systems and XCell™ ATF Single-use
6 and 10 devices using custom software
9. Allow the P-Box hardware and process parameters to be specific to the size of the
particular XCell™ ATF System being controlled.
Control principles are detailed in Section 6.
2.0 Utility Requirements
UTILITY
REQUIREMENT
ADDITIONAL CONSIDERATIONS
PRIMARY
COMPRESSED AIR
Maximum 90 psig /
6.1 bar
Oil free, dry, filtered gas, i.e., medical
grade air
SECONDARY
PRESSURE
Typically: 35 psi / 2.4bar,
Regulated oil free, dry, filtered air
VACUUM SERVICE
Minimum -12.5 psig
Vacuum supplied by a Repligen or
customer supplied local pump capable of
maintaining ~-12.5 psig with nominal
flow as follows:
XCell™ ATF4 - 40L/min
XCell™ ATF6 – 60L/min
XCell™ ATF10 – 200L/min
Pump should be clean room compatible
EXHAUST
Untreated discharge or user specified
ELECTRICAL
100-240V AC, 50/60Hz
NA
ENVIRONMENT:
Temperature: 0-50°C
Relative Humidity: 0 – 80
% RH
NA
STEAM (SIP)
~30lbs/hr.
Applicable only to a steamable
connection between XCell™ ATF and
bioreactor vessel
CONDENSATE DRAIN
For SIP condensate drainage
XCellTM ATF System with C410:V4B Controller User Guide
6
3.0 Dimensions and Weight
COMPONENT
DIMENSIONS
DESCRIPTION
H W D
C410v4B Controller
inches
PNEUMATIC BOX
13
10.5 8 Includes all plugs and connectors.
ELECTRIC BOX
24
24 9 (Controls) Includes all plugs and connectors.
POWER BOX
13
10.5
8
(Power Separation) Includes all plugs and connectors.
Filtration Assembly
Fully assembled system
XCell™ ATF 4 System
24 6 6x10
Indicated dimensions are estimates for the Filtration
Assembly, as the connection to the bioreactor, the
connections to the controller and to accessories can
affect height 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 10 Single-
use Device
38
18
16
C410v4B Controller
WEIGHT (Kg)
COMMENTS
PNEUMATIC BOX
~13
ELECTRIC BOX (Controls)
~23
POWER BOX
~12
(Power Separation)
Filtration Assembly
XCell™ ATF 4 System
~6
Weight does not include the weight of any
liquid, filter or connection between the
Filtration Assembly and the vessel
XCell™ ATF 4MC System
~14
XCell™ ATF 6 System
~14
XCell™ ATF 10lgcy System
~30
XCell™ ATF 10 System
~40
XCell™ ATF 6 Single-use
Device
~ 5
Does not include the weight of liquid and A2B
connectors
XCell™ ATF 10 Single-use
Device
~ 18
XCellTM ATF System with C410:V4B Controller User Guide
7
4.0 XCell™ ATF Pump Housing Assemblies
The Filtration Assembly of XCell™ ATF pump housing is shown 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 options for sanitary
diaphragm valves. All are available upon request.
Figure 4a. Exploded View of XCell™ ATF 10 System Filtration Assembly (P/N ATF10:PH‐GMP)
XCellTM ATF System with C410:V4B Controller User Guide
8
Table 4a. XCell™ ATF 10 Pump Housing Parts List
Note: C-CLAMP (Hemisphere) Items #20,21 should be torqued to 20-25 ft-lbs with 1" wrench flats
See Appendix 7 for list of spares and accessories
ITEM
DESCRIPTION
Material
QTY. 1
ASME Clamp, Assembly, XCell™
316 SS
2 2 Pump Hemisphere Air Side,
SA479 316L SS
1 3 Lifting Handle, Assembly, XCell™
316 SS
1
4 Pump Hemisphere Liquid Side,
316 SS
1
5 Filter Housing Assembly, XCell™
316 SS
1
6 Stand, Assembly, XCell™ ATF10
316 SS
1
7 Diaphragm, Pump, XCell™ ATF10
50A P.C. Silicone
1
8 0.295" C/S x 6.835" ID x 7.425" OD
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
EPDM
4
13
Sanitary Gasket, 1/2" TC
EPDM
3
14
Clamp, Sanitary 1/2-3/4" TC
304 SS
7 15
Sanitary Cap 3/4"
316 SS
2 16
Sanitary Diaphragm Valve, 1/2"
316 SS
3
17
Window, Sanitary 1.5"TC
AISI Type 316LSS
2
18
Pressure Gauge, 1.5" TC, 30 psi
SS
1
19
45 deg Elbow, 3/4" TC
SS
1
20
C Clamp w/ Lock-B, Assembly,
316 SS
3
21
C Clamp w/ Lock-A, Assembly,
316 SS
3
22
Air Inlet Filter, 0.2 micron, 1/2" TC
PVDF
1 23
Instrument Tee, 1.5" x 2X 3/4" TC
316 SS
1 24
Reducer, XCell™ ATF10
SA479 316L SS
1
25
Spectrum F10 2 Micron PES
NA
1 26
3/8” Hex Bit Socket, 3/8” Drive
Alloy Steel
1
XCellTM ATF System with C410:V4B Controller User Guide
9
Figure 4b. Exploded View of XCell™ ATF 10 Single-use Device with 0.2u PES Hollow Fiber Filter
XCellTM ATF System with C410:V4B Controller User Guide
10
Table 4b. XCell™ ATF 10 Single-use Device Components
Item
DESCRIPTION
MATERIAL
QTY
1
Housing Tube Assembly, suATF10
Polycarbonate (Lexan) HPS6
1
2
Spectrum F10 2 Micron PES Hollow Fiber
Cartridge
NA
1
3
0.295” C/S x 6.835” ID x 7.425” OD O-Ring, 50A
Hardness, Clear
Silicone
2
4
Reducer, Spectrum, su ATF10
Polycarbonate (Lexan)) HPS6
1
5
Liquid Side Pump Hemisphere Assembly, su
ATF10
Polycarbonate (Lexan) HPS6
1
6
Diaphragm, Pump, ATF10
50A P.C. Silicone: BlueStar LSR
4350
1
7
Pump Hemisphere, Air Side, suATF10
Polycarbonate (Lexan) HPS6
1
8
1”TC Bio Clamp, Glass Filled Nylon
GF Nylon
10
9
1” Silicone Sanitary Gasket
Silicone
4
10
Pump Lock Ring, suATF10
Silicone
1
11
GE ReadyMate to 1” TC
Polycarbonate
3
12
Sanitary Gasket, Silicone
Silicone
3
13
XCell ATF 10 Branding Label
Vinyl Decal
1
14
8” TC BioClamp, Glass Filled Nylon
GF Nylon
2
15
U Adapter, 1.5” Sanitary Fittings
PVDF
1
16
Aseptiquik x Insert, 1.5’ sanitary
Polycarbonate
2
17
Adapter, 1” MNPT x 1” Hosebarb
PVDF
1
18
Sanitary Fitting Adapter, 1” YC x 1” Hosebarb
PP
1
19
Steridyne 0.2um Filter Capsule, 1”x 3/4” TC
Flanges
PP
1
20
Oetiker Clamp, 1 3/8” to 1 1/2”
304 SS
1
21
Oetiker Clamp 1 15/64” to 1 23/64”
304 SS
1
22
High Pressure EVA tubing, 1” ID x 18” L
EVA
1.5FT
23
Bottom Lift Label, XcellsuATF10
Vinyl
1
24
Top Lift Label, XCell suATF10
Vinyl
1
25
Henkel Loctite AA-3944 UV Adhesive, 25ml
syringe
UV Adhesive
0.02
26
Bag, Poly Tube, LDPE, 6, mil x 30” x 500”
LDPE
8FT
27
Gamma Radiation Sterilization Indicator Labels
UV Indicator
2
28
Box, Shipping, Single Use ATF10
Cardboard & Foam
1
29
Tie Wrap
Nylon
14
30
Bubble Wrap, 6” x 300’
LDPE
11FT
XCellTM ATF System with C410:V4B Controller User Guide
11
Figure 4c. Exploded View of XCell™ ATF 6 System Filtration Assembly (P/N ATF6:PH‐GMP)
XCellTM ATF System with C410:V4B Controller User Guide
12
Table 4c. XCell™ ATF 6 Pump Housing Parts List
Item
DESCRIPTION
MATERIAL
QTY
1
Pump Hemisphere, Base Plate, Assembly, ATF6
AISI Type 316L
Stainless Steel
1
2
Socket Head Cap Screw, ¼-20 x 3/8 LG
18-8 SS
4 3 Pump Hemisphere, Air Side, ATF 6
SA479 316L SS
1
4
Socket Set Screw, Cup Point, 3/8-16 UNC x ½
LG
18-8 SS
1
5
Diaphragm, Pump, ATF6
50A p.c. Silicone:
BlueStar LSR 4350
1
6
Pump Hemisphere, Liquid side Assembly, ATF6
SA 479 316L SS
1
7
Sanitary Gasket, ½” TC
EPDM
4 8 Sanitary Diaphragm Valve, ½” w/TC ends
316 SS
3
9
Clamp, Sanitary ½”-3/4” TC
304 SS
6
10
Clamp, Sanitary 6.0”TC
AISI 304 SS
1
11
Filter Housing Assembly, ATF6
AISI type 316L stainless steel
1
12
Spectrum F^ 2 Micron PES Hollow Fiber
Cartridge
PC/PS w/Hollow Fibers
1
13
Silicone Size 337 70A O-Ring
Silicone
2
14
Sanitary Gasket, ¾” TC
EPDM
2
15
Pressure Gauge, ¾ TC 30 PSI to -30”Hg
ASI Type 316L stainless steel
1
16
Reducer, ATF6
SA 479 316L SS
1
17
Sanitary Gasket 1” TC
EPDM
1
18
Elbow 90 Deg-1.0, TC Ends
316 SS
1
19
Sanitary Cap ¾”
AISI Type 316L stainless steel
1
20
Sanitary Gasket 1 ½” TC
EPDM
2
21
Clamp Sanitary, 1 ½” TC
304 SS
3
22
Clamp, Sanitary, 3.0” TC, I Line Type
AISI 304 SS
2
23
Window, Sanitary 1/5”TC, With Rem. Glass
Insert
AISI Type 316L stainless steel
2
24
Sanitary Adapter, ¾” Tri-Clamp x ¼” Hose Barb
Fitting
AISI Type 316L Stainless Steel
1
25
Straight Thread/ Swivel Adapter, 3/8” Tube
9/16-18M x 9/16-18F
316 SS
1
26
Male Long Connector, 3/8” Tube OD, 9/16-
18M x ¼” NPTM
316 SS
1
27
45 Deg Female Pipe Elbow, ¼-18NPT x 1/4-NPT
316 SS
1
28
Air Inlet Filter w/1/4” NPT male ends ,& Filter
Vent Caps (2)
PVDF
1
See Appendix 7 for list of spares and accessories
XCellTM ATF System with C410:V4B Controller User Guide
13
Figure 4d. Exploded View of XCell™ ATF 6 Single-use Device with 0.2u PES Hollow Fiber Filter
XCellTM ATF System with C410:V4B Controller User Guide
14
Table 4d. XCell™ ATF 6 Single-use Device Components
Item
Item Description
Material
Qty
1
Pump Hemisphere: Air Side: XCell suATF6
Polycarbonate (Lexan)
HPS6
1
2
Diaphragm: Pump: ATF6
50A P.C. Silicone: BlueStar
LSR 4350
1
3
Pump Hemisphere: Liquid Side: XCell suATF6
Polycarbonate (Lexan)
HPS6
1
4
Housing Tube: XCell suATF6
Polycarbonate (Lexan)
HPS6
1
5
Reducer: XCell suATF6
Polycarbonate (Lexan)
HPS6
1
6
3/4" TC: Pump Hemisphere: Liquid Side: XCell
suATF6
Polycarbonate (Lexan)
HPS6
1
7
Spectrum F6 2 Micron PES Hollow Fiber Cartridge
N/A
1
8
Pump Lock Ring: XCell suATF6
Silicone
1 9 Permeate Port: Housing: XCell suATF6
Polycarbonate
2
10
Sanitary Gasket: 3/4" TC
Silicone
1
11
413 O-Ring: Class VI: 70A Silicone
Silicone
2
12
233 O-Ring: Class VI: 70A Silicone
Silicone
2
13
Air Inlet Filter w/1/4" NPT male ends (gamma
stable)
PVDF
1
14
Poly Tube: 1/4" ID x 3/8" OD: White
Polyurethane
18 in.
15
GE ReadyMate to 1" TC
Polycarbonate
3
16
GE ReadyMate to 3/4" TC
Polycarbonate
1
17
1" TC 90 Deg Elbow
PVDF
1
18
1" TC BioClamp
Glass Filled Nylon
8
19
0.75" TC BioClamp
Glass Filled Nylon
1
20
O-Ring: Size 207
Silicone
1
21
3/8" Tube Push-to-Connect x 1/4 NPT Male
PVDF
1
22
3/8" Tube Push-to-Connect x 1/4 NPT Female
PVDF
2
23
1" Sanitary Gasket
Silicone
4
24
XCell ATF 6 Branding Label
Vinyl Decal
1
25
Henkel Loctite AA-3944 UV Adhesive: 25ml syringe
UV Adhesive
1
26
Roll: Poly Tube: 6 Mil Heavy Duty: 20" x 500'
LDPE
1
27
Gamma Radiation Sterilization Indicator Labels
UV Indicator
1
XCellTM ATF System with C410:V4B Controller User Guide
15
Figure 4e. Exploded View of XCell™ ATF 4 System Filtration Assembly (P/N XCell™ ATF4:PH‐GMP)
XCellTM ATF System with C410:V4B Controller User Guide
16
Table 4e. XCell™ ATF 4 Pump Housing Parts List
Item
DESCRIPTION
MATERIAL
QTY
1
Pump Hemisphere, Air Side, ATF4
SA 479 31 6L SS
1
2
MS/SAE Male Straight Threaded Connector
7/16 - 20 x 3/8” tube OD
AISI Type 31 6L Stainless Steel
1
3
Tubing, Air Inlet Line, 3/8” SS x Tube x 2.5 LG
AISI Type 316 L stainless steel
1
4
Female NPT Connector, ¼ NPT x 3/8” Tube
OD
AISI Type 316L stainless steel
1
5
Air Inlet Filter w/ ¼” NPT male ends, & Filter
Vent Caps (2)
PVDF
1
6
Diaphragm, Pump, ATF4
50A P.C. Silicone: BlueStar
LSR4350
1
7
Pump Hemisphere Assembly, Liquid Side,
ATF4
AISI Type 316L stainless steel
1
8
Sampler Port Stem Assembly, ATF2/4
See pg.2
1
9
Clamp, Sanitary, 4” TC
AISI Type 316L stainless steel
1
10
Sanitary Gasket, 2 ½” TC
EPDM
2
11
Hollow Fiber Module
PC/PS w/Hollow Fibers
1
12
Filter Housing Assembly, ATF 4
AISI Type 316L stainless steel
1
13
GMP O-Ring, ATF4
Silicone
2
14
Reducer, ATF4
SA479 326L SS
1
15
Clamp, Sanitary, 3”TC
AISI Type 316L stainless steel
2
16
Silicone Tubing W/TC Ends, ATF2
Silicone
1
17
Clamp, Sanitary ½-3/4”” TC
AISI 304 SS
5
18
Sanitary Gasket, ¾” TC
EPDM
2
19
Sanitary Gasket, 1 ½” TC
EPDM
1
20
Window, Sanitary 1.5”TC, with/ Rem. Glass
Insert
AISI Type 316L stainless steel
1
21
Clamp, Sanitary, 1 ½” TC
AISI 304 SS
1
22
Pressure Gauge, ¾ TC 30PSI to -30” Hg
AISI Type 316L stainless steel
1
23
Sanitary Cap ¾”
AISI Type 316L stainless steel
1
24
Sanitary Gasket, 1.2” TC
EPDM
2
25
Sanitary Diaphragm Valve, ½” w/TC ends
AISI Type 316L stainless steel
1
26
Sanitary Adapter, ¾” Tri-Clamp x ¼” Hose
Barb Fitting
AISI Type 316L stainless steel
1
See Appendix 7 for list of spares and accessories
XCellTM ATF System with C410:V4B Controller User Guide
17
5.0 XCell
TM
C410v4B Controller Layout
5.1 General Layout
The controller consists of three major components:
-P-Box
-E-Box
-Power-Box,
Figure 5a/b/c/d shows the details.
The E-Box and the P-Box interconnected with a cable that relays signal and power. A general
layout with the XCell™ ATF System is shown in Fig. 5a. the primary design objective is to
produce a modular system that will maximize adaptability of the system to the various space
requirements of the user’s facilities. One can envision the P-Box in proximity to the Filtration
Assembly, while the E-Box positioned distant to the Filtration Assembly, possibly mounted on
a wall or a skid. A stainless steel cart, specifically designed to house the three controller
components, and supporting components (vacuum pump, peristaltic pump and paperwork) is
available for purchase.
Figure 5a. XCellTM C410v4B General Arrangement
XCellTM ATF System with C410:V4B Controller User Guide
18
5.2 Filtration Assembly (Stainless Steel)
This includes the Diaphragm Pump, Filter Housing, connection to the bioreactor, harvest line; pump
air inlet assembly, stand, plus all the housing accessories as specified in the part list. The housing is
not included with the controller.
5.3 Pneumatics Box (P-Box) Components
j. Pressure gauge (0 to 60psi, 0 to 4.1 bar)
k. Vacuum gauge (0 to -14psi, 0 to -0.95 bar)
l. System STOP Switch
m. Plugs for sensor inputs (4x4-20mA)
n. Interconnect Cable Plug (pneumatics)
o. Connection for Diaphragm Pump
p. Pressure regulator (0 to 60psi, 0 to 4.1 bar)
q. Connection for compressed air
r. Connection for vacuum supply
Figure 5b. Pneumatic Box Connections
5.4 Electrical Box (E-Box)
The E-Box contains the HMI and PLC components, including the Siemens S7-1200 PLC, programmed
using Siemens Step 7 Basic v13. The Operator Interface Terminal (OIT or HMI) is a Siemens SIMATIC
TP 1200 Comfort, programmed using Siemens WinCC Advanced v13.
XCellTM ATF System with C410:V4B Controller User Guide
19
Electrical Box Components
a. NA (not available for C410v4B controller)
b. Interconnected Cable Plug (pneumatics)
c. Interconnected Cable Plug (power)
d. Illuminated system stop button
e. n/a. Illuminated On/OFF switch relocated to power-box component u in C410v4B
f. HMI/OIT Display
g. n/a (not available for C410v4B controller)
h. Harvest Pump Relay Outputs (2)
i. Alarm Relay Outputs (2)
j. Ethernet connection port
k. Profibus connection port
Figure 5c. Electric Box (E-Box) Connections
XCellTM ATF System with C410:V4B Controller User Guide
20
5.5 Power Box (Power Separation) Components
s. Interconnected Cable Plug (power)
t. Mains power plug, 120/220 vac 60/50 hz
u. Illunminated On/Off switch
Figure 5d. Power Box Connections
†Note: The electric plug design may vary depending on geography
5.6 Primary Pneumatic Services
Air inlet (q) - 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 be required, as needed, to generate higher flow rates or to drive pneumatic
instruments.
Do not exceed 90 psi / 6.1 bar on the Air inlet
Exhaust/ vacuum line (r) - Located on the P-Box. Leaving the Exhaust outlet open to the
atmosphere or connected to a vacuum line, will depend on the type of process vessel used.
For a vessel that cannot be pressurized (e.g., some stainless steel vessels, glass vessels, SUB,
etc.), the line is connected to a vacuum source. For a vessel that is pressure rated, one may
use vessel pressure to drive the Exhaust cycle, particularly at low XCell™ ATF System flow
rates; but in case where vessel pressure is limited, or at high XCell™ ATF System flow settings,
a vacuum source supplement may be required.
Note: In addition to vessel pressure, the hydrostatic pressure generated by the height difference between
vessel liquid level and pump level may assist or hamper the exhaust flow
XCellTM ATF System with C410:V4B Controller User Guide
21
Pump line (o) - Located on the P-Box. The line connects the P-Box to the Diaphragm Pump. A
hydrophobic 0.2micron filter in this line provides both a sterile barrier and a potential barrier
to the back flow of liquid from Diaphragm Pump to controller should a diaphragm rupture.
Note: Be sure to use the hydrophobic filter in the pump line to prevent accidental flow 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 pressure to a specified, user required, value.
Note: Typically, the secondary air pressure is regulated to 35psi/2.4bar. That value is selected
because that pressure is recommended to drive the proportional pressure control valve PRV1 and
it is generally the upper limit of the pressure required to achieve set flow rates.
Air Pressure Gauge (j) - Located on the upper side of the P-Box. Typical range of gauge is 060psi. It shows second stage system pressure.
Vacuum Gauge (k) - Located on the upper side of the P-Box. Typical range of gauge is 0 to 14psi / -0.95 bar. It shows primary vacuum pressure status.
5.7 Primary Electric Services
Electric plug (t) - Located on the power separation portion of E-Box. Electric power (standard
100-240V AC, 60/50Hz).
Power switch (u) - Located on power separation portion of E-Box.
Power indicator Light (u) - same as the power switch. Lights green when power is ON
System Stop Button (d, l) - Located on the P-Box and E-Box.
Either System Stop Button causes the system to cease operation and default to Standby
mode. Here the Diaphragm Pump defaults to Exhaust.
System Stop Button is not an emergency stop.
5.8 Signal
A total of 4 Sensor input plugs (m) are provided on the P-Box. All inputs are analogue 420mA. Three plugs P3, P4 and P5 are for pressure inputs. One plug W1 is for a load Cell input.
Ethernet/Profibus (g) - communication port for data acquisition on E-Box.
Relays – Two relay outputs are for relaying alarm conditions (i). Two relays for driving a
harvest pump (h).
Interconnect (Signal) Cables (I-Cable) - to relay signal and DC power between E-Box and P-
Box.
XCellTM ATF System with C410:V4B Controller User Guide
22
6.0 C410v4B Controller Process and Control
6.1 Control Overview
When the pressure cycle starts, the pressure to the diaphragm pump rapidly increases (as
measured by the P2 pressure sensor in the controller). At some critical pressure, the
diaphragm begins to move and the PA begins to expand. As the PA expands, P2 levels off
and must be sustained to maintain the expansion of the PA. This critical P2 pressure is also
known as the “Driving Pressure” or “Driving Force” (DP or DF).
Once the PA is fully inflated, the pressure within the pump chamber will begin to spike;
e.g. the diaphragm stops moving and begins to stretch. The controller takes advantage of
this spike by using a cycle Switch Offset (SO) to indicate when to switch to the Exhaust
cycle. Similar mechanism applies to the Exhaust cycle.
To assure optimum results with the XCell™ ATF System, one should keep in mind the following
two general rules:
1. The diaphragm motion must be a continuous one between the Pressure cycle and the
Exhaust cycle and vice versa (i.e. no dwell time)
2. Ideally, the stroke travel of the diaphragm must be reversibly between fully Pressurized
and fully Exhausted extremes
Note: There should be no dwell time for the diaphragm at any point of the cycle.
XCellTM ATF System with C410:V4B Controller User Guide
23
The continuous movement of the diaphragm assures continuous tangential flow through
the filter. The maximum stroke of the diaphragm assures maximum mixing and minimizing
“dead space” retention within the system.
Control of the XCell™ ATF System is based on the above two rules.
The XCell™ ATF System, having a constant pump volume, allows the controller to calculate
the Diaphragm Pump cycle time based on a user’s flow rate selection, according to the
following relationship:
The programmed pump displacement volumes, with no pressure difference across the
diaphragm, are:
XCell™ ATF 4 System 0.44L
XCell™ ATF 4MC System 0.44L
XCell™ ATF 6 System 1.2L
XCell™ ATFXCell™ ATF 10lgcy System 5.1L
XCell™ ATF 10 System 6.0L
See also Appendix 1. Cycle time vs. Flow rate.
Therefore, selection of a Flow Rate (L/min) by a user, using an XCell™ ATF System with a
known Pump Displacement Volume (L), it is possible for the C410v4B controller to calculate
the Pump’s Cycle Time, Calculated CT.
At the end of each pump cycle, the Actual Cycle Time, Actual CT, is compared to the
Calculated CT. The controller then uses the error between the two values to correct Actual CT
to equal Calculated CT. Similarly, the C410v4B controller also allows the user to enter XCell™
ATF System cycle time (sec) directly to control flow rate; again, at the end of each pump cycle,
the Actual CT is compared to the Calculated CT. The C410v4B controller is designed to
maintain the set flow rate automatically during the Pressure and Exhaust pump cycles. Based
on an entered set point in either Liters per minute, LPM, or Time, in seconds, the C410v4B
controller will continually adjust the Pressure and Exhaust flow rates to match the entered set
point flow rate.
XCellTM ATF System with C410:V4B Controller User Guide
24
SOL1
INCOMING AIR
EXHAUST (VACUUM)
PROPORTIONAL VALVE
PV1
PRESSURE
SENSOR
P2
TO PUMP
PROPORTIONAL VALVE
PV2
AUTOMATIC
PRESSURE
REGULATOR
PRV1
MANUAL
PRESSURE
REGULATOR
AUTOMATIC
VACUUM
REGULATOR
PRV2
Figure 6. Instrument Flow Control Schematic of C410v4B Controller
XCell™ ATF System Flow control is achieved by regulating the pneumatic air flow to and
from the Diaphragm Pump; the pneumatic flow control is achieved with a two stage
control, by regulating its pressure and with a flow restrictor. Two Proportional Pressure
Regulators Valves, PRV1 and PRV2, are designed to make fine adjustments in pressure to
the air stream flowing from the manual pressure regulator to a flow restrictor. Two
automated flow restrictors, Proportional flow control Valves, PV1 and PV2, are designed to
make coarse adjustments in flow. Final flow control is achieved by Step changes in PV
orifice 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 proportional air pressure regulating valve, PRV1, and the exhaust pressure
regulating valve, PRV2, will be adjusted by the PLC based on the Error. The error will cause
pressures to be changed to affect the flow, positive or negative, respectively, to and from
the pump to match flow set point for the next cycle.
If the new value for PRV1 and/or PRV2 exceed their set pressure limits, (e.g. PRV1 0 to 30
psi, PRV2 0 to -14.5 psi), then, the respective PV1 and PV2 will adjust incrementally, (e.g.
by user defined increments (in the Basic Set Up Screen)), until the PRVs are back within
operational range.
6.2 Control Functional Algorithms
The C410v4B controller utilizes several algorithms to determine when the Diaphragm Pump
switches cycle direction. The principal method is based on first detecting a steady state
pressure phase or “Driving Force” during each pump cycle followed by addition of a Switch
Offset, i.e. a pressure increment (or spike). A cycle change is executed when actual pump
pressure (as determined by P2) is equal or greater than the sum of Driving Force pressure and
Switch Offset pressure.
XCellTM ATF System with C410:V4B Controller User Guide
25
The parameters and configuration within this manual should not be changed without
consultation with a Repligen representative. The controller, when properly maintained and
serviced, should be able to handle almost all cell culture conditions and viscosities.
Should you determine that the controller is not functioning correctly and exchanging the full
volume of the diaphragm pump with each stroke, please immediately contact Repligen for
further assistance.
6.3 Interface and Screens
A Siemens Operator Interface Terminal (OIT) provides the user with the following features:
1. Pump Status including cycle rate, flow rate, pressures, controller status and total batch
cycles
2. Setup Parameters
3. Acknowledge and clear machine faults (i.e. alarms)
4. Process Trending
When an input box is highlighted and pressed; a number pad or keyboard will appear on
screen to enable data input.
For numerical entries as the value is being typed, a Min and Max range dialog box appears,
showing the user the acceptable value range. Any value outside the min/max range, or any
text strings or letters is not accepted.
The OIT will display the following Primary Screens:
Primary Screens – INITIAL, MAIN, SET UP, ALARMS, TRENDING, BATCH, ADMINISTRATOR, LOG
OFF.
Secondary Screens – Screens imbedded within the Primary Screens.
Screen
Description
INITIAL
Initial System Log On which appears when the C410v4B controller first
powers up; unless configured to be “black box”
MAIN
Main Diaphragm Pump Control & Monitoring Displays Real Time Pump
Status Access to all Primary Screens.
SET UP
Users Set Up of Process parameters, Calibration, and Diaphragm Pump
Parameters
ALARMS
Display Diaphragm Pump Warnings and Faults
TRENDING
Graphical Real Time display of Flow Set Point, Exhaust Set Points, Flow
Process Value, Vessel Weight.
BATCH INFO
Batch Set Up Screen
ADMINISTRATION
Setting of users ID, security level and passwords, Close Application, PLC
ON/OFF
LOG OFF
Users logoff
XCellTM ATF System with C410:V4B Controller User Guide
26
Description of Screens and Buttons
A.
INITIAL
The Initial screen appears when the C410v4B controller is powered up. Press the Logon button to
bring up the User/Password Dialog Box and Keyboard. For first time use, enter ADMIN for USER
and 1234 for PASSWORD. Many of the main screen parameters are actively displayed (as read
only) on this screen for user convenience. Logging on is not required to observe remote control
operations.
XCellTM ATF System with C410:V4B Controller User Guide
27
The Main screen provides an overview of the XCell™ ATF process. It displays a
schematic/animation for pneumatic process, a diaphragm movement /cycle, valve transition
between pressure and exhaust cycles and flow direction. From the Main screen, an operator can:
1. Monitor and control XCell™ ATF System processes. In the Main screen and all subsequent
screens, all data fields with a white background are for display only. The operator, based
upon security levels, can change data fields with a beige background.
2. Start/Stop Diaphragm Pump
a. When 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 Pump, a dialog box will appear that enables the user to
confirm the stop command, or to cancel and return to the main screen.
3. Access other screens based upon password security levels
4. Observe P2 trending. A P2 Trend button hides /unhides this screen.
5. Observe an animated Diaphragm Pump showing pressurization (inflation) and exhaust
(deflation) cycles of the Diaphragm Pump.
6. Monitor Overtime condition- displayed in FLOW status sub screens, by change of actual
cycle time field to red
7. Monitor Overflow condition- displayed in FLOW status sub screens, by change of actual
cycle time field to orange
B.
MAIN
XCellTM ATF System with C410:V4B Controller User Guide
28
The main screen displays the parameters in the following tables:
Field
Description
Date/Time
Displays current Date and Time
User ID
Displays current User ID
Entries in Main
Screen
Field entries by Administrator (or, if authorized, by Engineer) through the
Main screen: P-FLOW SP, E- FLOW SP, PV1, PRV1, PV2, PRV2
P-FLOW SP
Displays current P-Flow Set Point (SP) (LPM)
P-FLOW PV
When running, displays pump Flow rate Process Value (PV) of last pump
cycle (LPM)
P-FLOW
Calculated
Displays current P-Flow Calculated cycle time (Sec)
P-FLOW Actual
When running, displays Actual pump flow cycle Time of last pump cycle
(Sec)
E- FLOW SP
Displays current E-Flow Set Point (SP) (LPM)
E- FLOW PV
When running, displays pump exhaust Flow rate Process Value (PV) of last
pump cycle (LPM)
E-FLOW
Calculated
Displays current E-Flow Calculated cycle time (Sec)
E-FLOW Actual
When running, displays Actual pump exhaust cycle Time of last pump cycle
(Sec)
PV1
Displays current position Set Point of Flow Proportional Valve (0-100%)
PV2
Displays current position Set Point of Exhaust Proportional Valve (0-100%)
PRV1
Displays current setting of automatic pressure regulator (0 to 35psi)
PRV2
Displays current setting of automatic exhaust regulator (-15 to 0 psi)
P2
Displays current pressure between controller and Diaphragm Pump (PSI)
Controller
Status
Displays current controller status:
PUMP OFF
INFLATING
EXHAUSTING
PUMP WARNING
PUMP ALARM
SYSTEM STOP
Indicator
Description
PLC
Indicates Controller PLC is ON and in RUN mode
Pump ON
Indicates Diaphragm Pump is in RUN mode
Standby
Indicates Controller OFF/ON Status
SOL 1
Indicates Flow Direction Solenoid is OFF/ON
Bioreactor
Connected Bioreactor ID (input in setup basic)
Batch
Batch ID information (input in Batch Info)
Runtime
Time the current batch has been running (reset in Batch Info)
Current User
Displayed username of current login
XCellTM ATF System with C410:V4B Controller User Guide
29
Button
Description
Start
Press to START Diaphragm Pump
Stop
Press to STOP Diaphragm Pump
P2 Trend
Press to toggle view the XCell™ ATF System Cycle (P2 Trend) Popup
All Primary
All Primary Screen Buttons are displayed to navigate to those screens.
Alarms, Trending, Batch Info, Set Up, Administration
Control Mode
Switches the controller from remote to local operation
When Starting the Diaphragm 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. same PRV and PV values as when the Diaphragm Pump last ran).
Default setting is preferred when starting the Diaphragm Pump with new flow rate settings or
new process setup (e.g. different bioreactor configuration & parameters). This minimizes the
number of cycles taken by the controller to reach the desired flow rate. At any selected flow rate,
default simply resets the control parameters to factory preset values.
Cancel will return to the main screen without any action taken.
When Stopping the Diaphragm Pump, the following dialog box will appear:
XCellTM ATF System with C410:V4B Controller User Guide
30
From the Set Up Screen, an Engineer/Administrator can make entries in the following:
• Basic Set Up Screen
• Help Guide
• Advance Set Up Screen
• Exit to Primary Screens
• Calibration Screen
• Navigate to the following Secondary
screens
From the Basic Set-Up Screen, an Engineer/Administrator can:
1. Set initial Controller Set Up
2. Change ‘Hi Hi’ and ‘Lo Lo’ Alarm set points
3. Change Process Parameters
4. Access other screens based upon password security levels
The Basic Set-Up screen will display the parameters in the following tables:
Field
Description
Controller Set Up
Groups the following fields:
Pump Model No
Press to select Pump Model No XCell™ ATF 4, 4MC, 6, 10lgcy, 10.
These settings apply to both stainless steel and single-use systems.
Control Mode
Press to select Control Set Point units (FLOW or TIME)
Alarm Delay(min)
The amount of time in minutes the controller will stay in warning
condition before switching to alarm condition. (If 0 is entered
system will remain in warning condition.)
Slope Function Enable
Integrates P2 slope at Delay Time to extrapolate Cycle Switch
Pressure.
C.
SET UP
C.1
BASIC SET UP
XCellTM ATF System with C410:V4B Controller User Guide
31
Field
Description
Bioreactor pressure
Expected bioreactor operating pressure
∆ height
The height difference between bioreactor liquid level and middle of
Diaphragm Pump (in cm)
Connected Bioreactor
Prefix
The Prefix assigned to the bioreactor connected to the XCell™ ATF
system.
P2 limits
Sets P2 upper and lower allowable limits
HiHi Alarm Set Points
Sets a high limit on P2 pressure during the P-Flow Cycle
If P2is ≥ HIHI, follow with ALARM and System Stop
LoLo Alarm 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 minutes, it will remain in a “Warning” state. If the field is
set 1 – 50 minutes, after that time elapses the system will go into an
“Alarm” state which will put system in a halt condition.
Pump Parameters
Groups Diaphragm Pump Parameters
P-Pressure Offset (psi)
Pressure cycle: Pressure Offset or-Over pressure Set Point (P-OSP1)
value (psi) above P2 to switch from Flow (or Pressure) cycle to
Exhaust
E-Pressure Offset (psi)
Exhaust cycle: negative Over pressure Set Point (E-OSP2) value (psi)
below P2 to switch from Exhaust cycle to Flow or Pressure cycle
P-Delay (%)
Sampling point of sP2 during the Pressure cycle (% of total cycle
time, preset range 10 to 90%)
E-Delay (%)
Sampling point of sP2 during the Exhaust cycle (% of total cycle time,
preset range 10 to 90%)
P-Overtime (%)
Sets the overtime limit to the Pressure cycle (% of calculated cycle
time)
E-Overtime (%)
Sets the overtime limit to the Exhaust cycle (% of calculated cycle
time)
P-PV Step Size (%)
Sets the (%) incremental change in PV1 when PRV1 exceeds its set
limits
E-PV Step Size (%)
Sets the (%) incremental change in PV2 when PRV2 exceeds its set
limits
Button
Description
Advance Set Up
Press to switch to Advanced Set Up Screen
Help Guide
Press to switch to Start up (Help) Guide Screen
Calibration
Instrument Calibration
Accept / Discard
Change
Accept Change and Discard Change to accept or reject any
parameter change on the screen.
All Primary
All Primary Screen Buttons are displayed to navigate to those
screens
XCellTM ATF System with C410:V4B Controller User Guide
32
From the Advanced Set Up Engineer/Administrator can set the following Diaphragm Pump
Parameters:
C.2
ADVANCED SET UP
XCellTM ATF System with C410:V4B Controller User Guide
33
The Advanced Set-Up screen will display parameters in the following tables:
Field
Description
Max P-FLOW (LPM)
Maximum limit for Pressure FLOW set point (LPM)
Max P-FLOW (sec.)
Maximum limit for Pressure FLOW set point (Seconds)
Min P-FLOW (LPM)
Minimum limit for Pressure FLOW set point (LPM)
Min P-FLOW (sec.)
Minimum limit for Pressure FLOW set point (Seconds)
Max E-FLOW (LPM)
Maximum limit for Exhaust FLOW set point (LPM)
Max E-FLOW (sec.)
Maximum limit for Exhaust FLOW set point (Seconds)
Min E-FLOW (LPM)
Minimum limit for Exhaust FLOW set point (LPM)
Min E-FLOW (sec.)
Minimum limit for Exhaust FLOW set point (Seconds)
PV1 Max (%)
Maximum operating limit for PV1 (%)
PV1 Min (%)
Minimum operating limit for PV1 (%)
PV2 Max (%)
Maximum operating limit for PV2 (%)
PV2 Min (%)
Minimum operating limit for PV2 (%)
PRV1 Max (psi)
Maximum operating limit for PRV1 (psi)
PRV1 Min (psi)
Minimum operating limit for PRV1 (psi)
PRV2 Max (psi)
Maximum operating limit for PRV2 (psi)
PRV2 Min (psi)
Minimum operating limit for PRV2 (psi)
Button
Description
Basic Set Up
Press to switch to Basic Set Up Screen
Help Guide
Press to switch to Start Up Guide Screen
Calibration
Instrument Calibration
Accept / Discard
Change
Accept Change and Discard Change to accept or reject any
parameter change on the screen.
All Primary
All Primary Screen Buttons are displayed to navigate to those
screens
XCellTM ATF System with C410:V4B Controller User Guide
34
The Start Up Guide page shows a Quick reference guide for the operator. This information
should be reviewed by all Users before operating the C410v4B controller.
The Start Up Guide screen does not display parameters. Navigation buttons are described in
the following table:
Button
Description
Basic Set Up
Press to switch to Basic Set Up Screen
Advanced Set Up
Press to switch to Advanced Set Up Screen
Calibration 1
Equipment Calibration
All Primary
All Primary Screen Buttons are displayed to navigate to those
screens
C.3
START-UP GUIDE
XCellTM ATF System with C410:V4B Controller User Guide
35
Analog Input Configuration / Calibration: Only accessible to the Administrator and Engineer
Login. The Analog Input Configuration / Calibration screen allows for the setup of analog inputs.
For each analog input the Administrator and Engineer will be able to configure the
Engineering Units, the Minimum Engineering Value, the Maximum Engineering Value, and
perform a two point calibration (or linear scaling).
The Calibration screen will display parameters in the following tables:
Field
Description
Entries on Screen
Field entries: (14)Eng. Units, PV1, PRV1, PV2, PRV2
Eng. Units (14 places)
Enter the Minimum Engineering Value for the selected analog input
to the left of 1st Point; and the Maximum Value to the left of 2nd point
Actual Value
Displays input value after the two-point calibration is performed.
PV1
Displays current position Set Point of Flow Proportional Valve (0100%)
PV2
Displays current position Set Point of Exhaust Proportional Valve (0100%)
PRV1
Displays current setting of automatic pressure regulator (0 to 35psi)
PRV2
Displays current setting of automatic exhaust regulator (-15 to 0 psi)
P2
Displays current pressure between controller and Diaphragm Pump
(PSI)
C.4
CALIBRATION
XCellTM ATF System with C410:V4B Controller User Guide
36
Button
Description
Analog Input Select
This button enables which of the Analog Inputs is selected for 2-point
linear scaling.
Capture (1st Point)
This button captures the raw input value for the first point for the
selected analog input
Capture (2nd Point)
This button captures the raw input value for the second point for the
selected analog input
Accept Settings
This button will enable the new settings. Exiting the screen without
Accepting the settings will discard them. It is only visible after both
1st point and 2nd point have been captured.
Applies to calibrating (scaling) the above 7 analog inputs
Sol. Force
Allows manual control of Flow Control Valve, SOL1; with that
controlling flow direction of pneumatic system.
PRV2 Min Check box
While checked, the following is set:
1) The solenoid is set to the vacuum position
2) PV2 is commanded to 100%
3) PRV2 is commanded max vacuum
The readout of the P2 sensor is displayed to the right
Accept
This button provides the measured P2 value to the controller (also
displayed on the advanced Set Up screen) as the minimum PRV2
setting.
Pressing this accept button also unchecks the above check box,
setting the solenoid, PV2 and PRV2 to their previous values.
Basic Set Up
Press to switch to Basic Set Up Screen
Advanced Set Up
Press to switch to Advanced Set Up Screen
Help Guide
Press to switch to Start Up Guide Screen
All Primary
All Primary Screen Buttons are displayed to navigate to those screens
The pump must be off with the controller in Local mode to reach this screen.
WARNING:
Do not turn the Sol. Force to the ON position when the XCell™ ATF is connected to the
P-box (with air pressure utility). Doing so may over expand the diaphragm causing
potential breach.
XCellTM ATF System with C410:V4B Controller User Guide
37
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 in Liters
per Minute( LPM).
D.
TRENDING
D.1
PROCESS TREND
XCellTM ATF System with C410:V4B Controller User Guide
38
The Process Trend screen monitors, in real time, the Flow and Exhaust Set Points and Process
Values in LPM. The screen has the following screen control options:
Field
Description
Max
Enter maximum value for the chart Y Axis
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 the displayed time section
Zooms out of the displayed time section
Scrolls back one display width
Scrolls forward one display width
Starts or continues trend recording
Stops trend recording
Primary
Screens
All Primary Screen Buttons are displayed to navigate to those screens
D.2
PV, PRV, P2, P3, P4, P5, W1 TREND
XCellTM ATF System with C410:V4B Controller User Guide
39
These screens monitor, in real time, the specific analog signal. Trend buttons select trend to
display. All screens have the following screen control options:
Field
Description
Max
Enter maximum value for the chart Y Axis
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 the displayed time section
Zooms out of the displayed time section
Scrolls back one display width
Scrolls forward one display width
Starts or continues trend recording
Stops trend recording
Primary Screens
All Primary Screen Buttons are displayed to navigate to those screens
XCellTM ATF System with C410:V4B Controller User Guide
40
Weight TREND
Available in the TRENDING screen
During the XCell™ ATF System cycle, the weight of the Filtration Assembly changes in response
to the liquid flow to and from Diaphragm Pump. The weight profile is directly proportional to
the position of the diaphragm within the Diaphragm Pump which drives how much liquid is in
the Diaphragm Pump. This provides useful real time information on the position of the
diaphragm within the Diaphragm Pump, which is indicative of the cycle time and the
effectiveness of the pressure and vacuum cycles.
That information may be used to:
i. Monitor if the diaphragm cycles its full stroke.
ii. Display the position of the diaphragm in the Diaphragm Pump.
XCellTM ATF System with C410:V4B Controller User Guide
41
The Operator can view C410v4B controller Warnings and Alarm conditions. All
Alarms/Warnings are displayed with Time/Date stamping and full description of condition.
Both Alarms and Warnings will activate the audible horn located inside C410v4B controller
cabinet. An Alarm condition will automatically stop the pump cycling action, while a Warning
condition allows the pumping cycling action to continue. Warning and Alarm conditions are
described in the following section.
The Alarm screen will display parameters in the following tables:
Field
Description
Time
Indicates time of Alarm
Date
Indicates Date of Alarm
Text
Describes Alarm
Button
Description
Horn Acknowledge
Press to turn off Horn
Select Highlight Warning/Alarm message and press to remove
All Primary
All Primary Screen Buttons are displayed to navigate to those screens
E.
ALARMS
XCellTM ATF System with C410:V4B Controller User Guide
42
Two (2) Pump Controller Status Relays are provided which energize per the following states:
XCell™ ATF System
States
State #
RELAY #1
RELAY #2
POWER OFF / ALARM
A
OFF
OFF
POWER ON /
STANDBY
B
OFF
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
OFF
An isolated Form C contact for each relay is provided for the end user to connect to any
remote monitoring system. The Harvest pump is activated to Run mode, only and only if
Relay #1 is ON, i.e. in Power On/ Running state #C or Power On / Warning state #D.
The following is a list of C410v4B controller Warnings that can occur during normal operation:
• Flow Set Point cannot be reached. P-Flow Regulator (PV1) above maximum operating
setting.
• Flow Set Point cannot be reached. P-Flow Regulator (PV1) below minimum operating
setting.
• Exhaust Set Point cannot be reached. E-Flow Regulator (PV2) above maximum operating
setting.
• Exhaust Set Point cannot be reached. E-Regulator (PV2) below minimum operating
setting.
• P2 Pressure below Lo Lo Limit.
The following is a list of C410v4B controller Alarms that can occur during normal operation:
• XCell™ ATF System Warning has not been acknowledged. XCell™ ATF System function
halted.
• Main Power Loss (120/220) while Diaphragm Pump was running.
• P2 Pressure Above HI HI Limit
XCellTM ATF System with C410:V4B Controller User Guide
43
Great care should be exercised when altering parameters located on the screens described in
this section. Only accessible to the Administrator who can navigate to the following screens:
The screen allows creation/amending of User ID’s and passwords.
There are three (3) levels of security:
1. Administrators
2. Engineer
3. Operator
• One (1) Administrator Level User [Admin]
• Several Engineer Level User [Eng1], [User22], [User23], [User24], …[User76]
• Several Operator Level User [Oper1], [User1], [User10], [User11], …[User21]
Only administrators have security access to add/edit/delete all other User ID’s by touching the
appropriate fields.
Each User ID includes a field for Logoff Time (in minutes). When the time of inactivity is
reached, the current user will automatically be logged off. Access to other screens will prompt
the user to log in again. To disable this feature, a time value of 0 can be entered into the Logoff
Time Field.
F.
ADMIN.
F.1
USERS
XCellTM ATF System with C410:V4B Controller User Guide
44
The Administration screen will display parameters in the following tables:
Field
Description
User
Enter User ID
Password
Enter Password
Group
Enter Group No. to define security level
Log Off Time
Set the amount of time in minutes before current user is automatically
logged out. A value of zero will disable this feature.
Button
Description
All Primary
All Primary Screen Buttons are displayed to navigate to those screens
Basic
Navigates to ADMIN Basic Screens
Each level of security allows different levels of access to the C410v4B controller control
functionality please refer to Appendix 2 for details.
XCellTM ATF System with C410:V4B Controller User Guide
45
The Administration screen will display parameters in the following tables:
Field
Description
Software Version
Both PLC “4.36” (as shown) and HMI “4.36” (as shown) version numbers
are displayed.
ATF Number
Numerical entry allowing end users to identify ATF controller.
No of Pump
Cycles
Total number of pump cycles of all batches since reset
Profibus Node
Address
Defaulted to 2. This entry field allows for selecting alternate node
addresses.
Pressure
Engineering Units
Either PSI (as shown) or Bar
Display
Date/Time
Either Display (as shown) or Hide. Selecting Hide removes the Date/Time
display from all screens. This was installed in the event that the system
time had lost time synchronization with a central manufacturing system,
but customer request. This value is retained during a power loss of the
controller, making this selection permanent.
CPU
Either RUN (as shown) or Stop
F.2
BASIC
XCellTM ATF System with C410:V4B Controller User Guide
46
Field
Description
Power Restart
Mode
Either Idle (as shown) or Resume. This directs controller activity upon
controller power up. Resume will direct the controller to attempt to
continue ATF pumping [after complete boot up] at the last known flow
setpoint. Idle will not attempt to start the pump. Repligen recommends
leaving this idle for safety reasons.
Logon On Splash
Either ON (as shown) or OFF. Selecting OFF will not display the Logon
button on the Initial screen. This retained value should only be set to OFF
if users expect complete remote operations. Once this is set to OFF, it
cannot be returned to the on state except by Repligen personnel.
Repligen recommends leaving this in the factory set state.
Remote Mode
Connection
Either Profibus (as shown) or OPC. This slider switch selects which type
of connection is in command the PLC when in remote mode. All soft
outputs are provided to both sources and may be read from the PLC,
however only one of these shall be in command of the PLC.
Start Mode
Either Remote (as shown) or Local. This slider switch selects whether the
system will start up in (after power up) in remote control or local (HMI)
control.
Button
Description
Clean Screen
Siemens Touch Panel (HMI) utility which temporarily deactivates the
touch screen. Intended to allow cleaning of the screen without activating
any buttons.
Calibrate
Touchscreen
Siemens Touch Panel (HMI) utility fine tunes the touch locations on the
screen.
Set Date
Allows direct date setting without closing the XCell™ ATF application.
Set Time
Allows direct time setting without closing the XCell™ ATF application.
Display
Date/Time
Selector switch: Described in Field Description
CPU RUN
Places the PLC in RUN mode.
CPU STOP
Places the PLC in STOP mode.
Power Restart
mode
Selector switch: Described in Field Description
Logon On Splash
Selector switch: Described in Field Description
Remote Mode
Connection
Selector switch: Described in Field Description
Start Mode
Selector switch: Described in Field Description
Change Node
Changes the Profibus node to the value entered to the right. This should
only be changed by authorized personnel
P3 PV
Selector switch: Display or Hide Input value on Main screen
P4 PV
Selector switch: Display or Hide Input value on Main screen
XCellTM ATF System with C410:V4B Controller User Guide
47
Button
Description
P5 PV
Selector switch: Display or Hide Input value on Main screen
Scale PV
Selector switch: Display or Hide Input value on Main screen
PSI or BAR
buttons
Only visible in local mode, when XCell™ ATF pump is stopped and no
calibration activities are enabled. Select one to display alternate
engineering units.
OPC Inputs
Displays user defined OPC input parameters, addresses and values
OPC Outputs
Displays pop-up screen of OPC output parameters, addresses and values
Input Page 0-4
Displays user defined Profibus inputs by page of parameters, addresses,
values and feedback values
Output Page 0-5
Displays Profibus outputs by page of parameters, addresses and values
Calibration
Displays calibration settings in the PLC.
Users
Navigate to the Users Screen
All Primary
All Primary Screen Buttons are displayed to navigate to those screens
Close Application
Exits the HMI program; allow access to Windows CE settings screen.
XCellTM ATF System with C410:V4B Controller User Guide
48
Display batch information as in the following screens
The Batch Info Overview screen will display parameters in the following tables:
Field
Description
Batch Data
Displays current Batch information
Elapsed Time
Displays Elapsed 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 Up
Set Batch Name and reset Cycle count
Name
Click on field to change batch name
Button
Description
Cycle Count - Reset
Resets Cycle count to zero in Batch Data field
Algorithm
Navigates to Batch Algorithm Screens
All Primary
All Primary Screen Buttons are displayed to navigate to those
screens
G.
BATCH INFO.
G.1
OVERVIEW
XCellTM ATF System with C410:V4B Controller User Guide
49
XCell™ ATF System cycle change can occur by either of three algorithms. The screen tracks cycle
change Algorithm performance. The three Algorithms are:
1. Set Point - normal process based on set up parameters.
2. Overtime - when P2 Set Point is not achieved in within 120% of calculated time.
3. Overflow - When P2 reaches P1 (+/- OSP) within the set delay time.
The Batch Info Algorithm screen will display 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 Exhaust cycle counts
Overtime
Shows cycle count triggered by Overtime, tracks Pressure cycle and
Exhaust cycle counts
Overflow
Shows cycle count triggered by Overflow, tracks Pressure cycle and
Exhaust cycle counts
Button
Description
Reset Count
Resets all counts, by Set Point, Overtime and Overflow to zero
Overview
Navigates to Batch Overview Screens
All Primary
All Primary Screen Buttons are displayed to navigate to those
screens
G.2
ALGORITHM
XCellTM ATF System with C410:V4B Controller User Guide
50
On User logoff, the controller continues to operate normally. A user must log back on to make
changes to setting.
6.4 Startup
Assembly of the XCell™ ATF System is described in the following sections. This section
provides a startup guide for an XCell™ ATF System connected to a bioreactor and ready for
use, with the following general conditions:
• An XCell™ ATF 6 System is used in this example.
• An XCell™ ATF System flow of 12L/min is required.
• Bioreactor pressure is 0.0psi
• ∆ height between pump midpoint and vessel liquid level is 0cm
• Regulated air pressure set to 35psi
• Vacuum source connected
6.4.1 Following LOGON and entry of BATCH Information, go to the SET UP screen.
6.4.2 Go to the BASIC SET UP screen and enter the following field values.
Field
VALUE
Controller Set UP
Pump Model No
Select XCell™ ATF 6
Control Mode
Select FLOW
Slope Function Enable
Do not enable
Bioreactor pressure
0
∆ height (cm)
0
Alarm Delay(min)
1
Alarm Set Points
HiHi Alarm Set Points
7 psi
LoLo Alarm Set Point
-7 psi
Alarm Delay (x10 msec)
50 for both
Pump Parameters
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 Size (%)
3
E-PV Step Size (%)
3
6.4.3 Press Accept Changes.
H.
LOGOFF.
XCellTM ATF System with C410:V4B Controller User Guide
51
6.4.4 Go to the ADVANCED SET UP screen and enter the following field values
Field
VALUES
User Set Point Range
XCell™ ATF
4
XCell™ ATF
4MC
XCell™
ATF 6
XCell™ ATF
10lgcy
XCell™ ATF
10
Max P-FLOW (LPM)
10
10
20
80
100
Min P-FLOW (LPM)
1 1 5
20
20
Max E-FLOW (LPM)
10
10
20
80
100
Min E-FLOW (LPM)
1 1 5
20
20
PV1 Max (%)
95
PV1 Min (%)
5
PV2 Max (%)
95
PV2 Min (%)
5
Output (CV) Limits
PRV1 Max (psi)
25
PRV1 Min (psi)
1
PRV2 Max (psi)
-1
PRV2 Min (psi)
-12.5
Note: Min and Max E and P flow set points do not change to Time values when Control
Mode is changed to time
6.4.5 Press Accept Changes.
6.4.6 Go to the MAIN screen enter:
Field
VALUES
P-FLOW Status
SP (Lpm)
12
E-FLOW Status
SP (Lpm)
12
6.4.7 Note that PV and PRV fields are populated
6.4.8 Check all XCell™ ATF System connections.
6.4.9 Press START
Once the system begins to cycle, Note the following:
• The deviation of Actual Flow from Set Flow. The deviation between the two should be small.
Following a few cycles, the Actual and Set Flows should be similar.
• Note if in P-Flow block, Actual Cycle Time field is flashing Orange or Red; the same for
the E- Flow block, Actual Cycle Time field. If not flashing, the system is functioning
properly. If flashing remains, stop the controller and recheck all entries and
connections than restart. If problem persists, check the following:
XCellTM ATF System with C410:V4B Controller User Guide
52
a. The ∆P between PRV1-P2 should be greater than P-Pressure 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 readily
detected on the P2 trend by a rapid decline in pressure following a stable
pressure profile. (The Pump exhausts too rapidly followed by a rapid pressure
drop). Decrease PV2 or PRV2 to decrease flow as a corrective measure.
• Select the P2 trend in the MAIN screen and observe P2 profile, The P-Pressure Offset
and the E-Pressure Offset should be apparent.
Any adjustments in P2 trend on the Main screen are performed from the P2 TREND screens
6.5 Examples
XCell™ ATF System process control settings will depend on the process requirements. Each
user or process may have its own unique requirements. Hopefully, the example provides a
guideline to assist the users in selecting and optimizing operating conditions.
When working with an XCell™ ATF System connected to an unpressurized vessel, refer to
Figure 1 for an overview of positioning the Filtration Assembly, P-Box and E-Box relative to
the bioreactor.
Example 1
Using an unpressurized bioreactor with an XCell™ ATF 6 System:
When using a bioreactor that cannot be pressurized such as a glass vessel or a disposable
vessel, i.e., SUB, the connection between the Filtration Assembly and the SUB will most
likely not be an SIP type connection shown in Figure 1. Placement of the Filtration Assembly
and controller relative to the bioreactor will, however, not change significantly.
Using a vessel that cannot be pressurized, both pressure and vacuum services are needed.
See Utility Requirements, Section 2.
Repligen Corporation offers custom, disposable connections to most commercial SUBs. The
connection procedure between the Filtration Assembly and vessel are provided separately.
Start
1. Connect the Filtration Assembly to bioreactor per separate instructions.
2. Place the P-Box in proximity of the Filtration Assembly.
3. Connect Signal cable between E-Box and P-Box.
4. Connect E-Box to an appropriate electrical power source
5. Connect the Air Line, Exhaust Line and Pump Line to their respective ports on the P-
BOX. Do not connect the Pump Line from the C410v4B controller to the
Diaphragm Pump at this point.
6. Power ON the E-Box. Wait for system to boot up and display the XCell™ ATF System
INITIAL screen.
XCellTM ATF System with C410:V4B Controller User Guide
53
7. After LOGON, the main screen is displayed. Proceed to the SET UP screen.
8. Enter settings as in section 6.4.
Note XCell™ ATF System selection - Select XCell™ ATF 6 System. Note reactor pressure and ∆
height- enter 0 and measured difference between Diaphragm Pump clamp and vessel liquid
level in cm.
9. Power up compressed Air and Vacuum services, confirm pressure and vacuum
services are on by observing the respective pressure gauges.
10. Connect pneumatic Pump Line to Diaphragm Pump air filter.
11. Activate the P2 trend on the MAIN screen. (Any setting adjustments in the P2 screen
are made from the P2 TREND screen).
12. Press the START button on the MAIN screen.
13. XCell™ ATF System should begin cycling normally.
14. Observe for conditions described at the end of the last section.
Note the air purge from the system after start of XCell™ ATF System. Note also the small up and
down change in vessel liquid level, indicating XCell™ ATF System cyclic flow.
Changing flow rate:
To change flow rates, simply go to the main screen select P-Flow SP. Enter the new flow rate on
the pup-up menu. Press Yes to accept current PV and PRV values or press Default to accept
default PV and PRV values. Default is recommended when entering new flow rates. Follow
similar procedures to change E-Flow SP. It is recommended to STOP the controller prior to
change of flow rate. Following the change, re-START the controller. It will start with the
diaphragm in the fully exhausted position.
Filtrate or Harvest:
Start the Filtrate (or Harvest) pump only after XCell™ ATF System flow has stabilized. Stop the
Filtrate / Harvest pump when stopping the XCell™ ATF System flow; accordingly, the C410v4B
controller provides relay outputs on the E-BOX for activating or deactivating a filtrate / harvest
pump.
Please contact your local Repligen Account Manager to obtain additional technical assistance
with automation/integration related information.
XCellTM ATF System with C410:V4B Controller User Guide
54
7.0 XCell™ ATF Hollow Fiber Module and Diaphragm Replacement
The following is a guideline for replacing a Hollow Fiber Module (HFM) or the diaphragm within the
Diaphragm Pump. Since the procedures for replacing these parts are similar, a generalized description is
provided. Where necessary, more specific references and descriptions will be provided.
Example 2
Replacing 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 Separating the Filtration Assembly from the bioreactor
7.1.1 STOP the C410v4B controller.
7.1.2 Stop the filtrate / harvest pump.
7.1.3 Disconnect Diaphragm Pump pneumatic line from the pump air inlet filter.
7.1.4 Close or disconnect compressed air and vacuum services from the P-BOX.
7.1.5 Disconnect any sensors from the Filtration Assembly to P-BOX
7.1.6 If necessary, remove the P-BOX from the proximity of the Filtration Assembly.
7.1.7 Close and disconnect the filtrate line.
7.1.8 Disconnect the Filtration Assembly from the vessel as follows:
a1. Securely close both bivalves connecting the Filtration Assembly to the vessel.
a2. Drain liquid from the connection. Optionally, purge the connection with water, steam or
some other medium.
a3. Disconnect the Filtration Assembly from vessel between the two bivalves.
a4. Remove the Filtration Assembly to an appropriate work area, i.e., a sink.
7.2 HFM removal
7.2.1 Drain the system into an appropriately sized drain or waste vessel.
7.2.2 Remove all sensors from the Filter Housing
7.2.3 Remove air inlet filter connected to the Diaphragm Pump and any other connections
to the XCell™ ATF System
7.2.4 Open the clamp connecting the Filter Housing to the Diaphragm Pump and separate
7.2.5 Open the clamp connecting the Reducer to the Filter Housing and separate
7.2.6 The HFM may then be removed from the Filter Housing by firmly pressing it from one
end
7.2.7 Remove the exposed “O” ring at the exposed end of the HFM
7.2.8 Press the HFM in the opposite direction to remove the HFM
1.2.9 Prepare Filter Housing for cleaning and reuse or for cleaning and setting aside
XCellTM ATF System with C410:V4B Controller User Guide
55
7.3 HFM insertion
Prior to use, HFM may require wetting with water or buffer. In general, prior to use, please read
the separate Hollow Fiber Module 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 XCell™ ATF System; accordingly, two types of Filter
Housings are available:
• S-line Housing for use with HFM with “O” rings on the HFM ends for sealing against
the housing inner diameter.
• I-line Housing for use with HFM with no attached “O” rings. The “O” ring is placed
in a recess at the housing ends, between HFM and Reducer (or Diaphragm Pump).
Clamping the connection between Reducer (or Diaphragm Pump) and the Filter
Housing squeezes the “O” ring effectively forcing the “O” ring against the filter
wall, effectively sealing the three parts.
Figure 8. Types of Filter Housings
1.3.1 S-Line HFM insertion:
b1. Lay the Filter Housing horizontally and insert HFM (without “O” rings) into the
Filter Housing.
Step b2 is to avoid damage to the “O” ring during its insertion and sliding into the housing,
to avoid crossing the Harvest port opening during insertion, as the Drain port is close to the
housing end.
b2. Expose HFM at the Filter Housing end distant to drain port, in proximity to the
Filtrate / Harvest port.
b3. Place an “O” ring in the exposed HFM “O” ring groove.
XCellTM ATF System with C410:V4B Controller User Guide
56
b4. Press the HFM with “O” ring firmly into the housing.
Assure the “O” ring is inserted smoothly and uniformly. Lubricate with WFI to facilitate this
process.
b5. Press until the HFM “O” ring groove is exposed at the other end, the Drain nozzle
end.
b6. Place 2nd “O” ring on the exposed end.
b7. Press the HFM back into the Filter Housing until both “O” rings seal against the
housing ID.
b8. Assemble the system.
1.3.2 I-Line HFM insertion:
c1. Stand the Filter Housing vertically, with harvest port up.
c2. Insert the HFM into the housing
c3. Insert one “O” ring into the groove formed between HFM and Filter Housing end-
ferrule wall.
c4. Place the reducer onto the end, forcing the “O” ring into the groove.
c5. Clamp the reducer to the housing, the compressed “O” ring is forced against the
HFM. A seal is formed between the Housing, Reducer and HFM
c6. On the other end of the Filter Housing, Place the second “O” ring into the formed
groove between HFM and Housing end-ferrule.
c7. Carefully place the Filter Housing onto the Diaphragm Pump, forcing the “O” ring
deeper into the groove.
c8. Clamp the Filter Housing to the Diaphragm Pump.
c9. Assemble the XCell™ ATF System.
7.4 Screen Module replacement
If the SM is being used, contact Repligen at Customer Service at Sales@Repligen.com for
replacement instructions.
7.5 Diaphragm replacement
Replacement or placement of a diaphragm within the Diaphragm Pump is part of the Diaphragm
Pump assembly process which differs slightly among the XCell™ ATF 4 System, XCell™ ATF 6 System,
XCell™ ATF 8 System and XCell™ ATF 10 System.
Diaphragm Replacement Procedure for the XCell™ ATF 4 System, XCell™ ATF 6 System and XCell™
ATF 8 System
d1. Place cleaned Diaphragm Pump hemispheres, diaphragm and pump clamp on a table top
d2. Place the PL pump hemisphere (hemisphere with a nozzle on the side) with the large
opening in the upward position.
XCellTM ATF System with C410:V4B Controller User Guide
57
d3. Place diaphragm, pointing down into the PL pump hemisphere with the nipple of the
diaphragm orientated towards the ceiling. Assure the diaphragm gasket “O” ring is
positioned uniformly about the periphery of the pump “O” ring groove.
d4. Mate the PA-pump hemisphere, wide opening down, with the diaphragm in PL pump
hemisphere. Assure the diaphragm gasket “O” ring is positioned uniformly about the
periphery of the PA “O” ring groove.
d5. The two hemispheres, with diaphragm in between, should be equally spaced.
d6. Clamp the two hemispheres together.
d7. Secure the Diaphragm Pump to the stand.
Diaphragm Replacement Procedure for the XCell™ ATF 10 System
e1. The diaphragm within the Diaphragm Pump of the XCell™ ATF 10 System contains a short
right-angle bend on the diaphragm periphery which mates with a counterpart groove in
the PA pump hemisphere flange; therefore, for the XCell™ ATF 10 System, these two parts
are assembled first. The two Diaphragm Pump hemispheres are assembled with the
diaphragm pointing into the PL pump hemisphere.
e2. 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.
e3. Uniformly and sequentially tighten the clamps, so the diaphragm is compressed evenly
about the periphery of the two pump spheres.
e4. Add the second set of short C-clamps as described above.
e5. Add on the air inlet assembly to the Air inlet nozzle on the PA part.
e6. Carefully invert the assembled pump sphere, so it stands on the long C-clamps.
e7. One may place the pump onto its stand and/or proceed to assemble the entire system.
e8. Torque Settings: ASME clamps: torque to 30 lbft, C-clamp assemblies: torque 20-25lbft
7.6 Assembly
Fully assemble Diaphragm Pump, Filter Housing, reducer and accessories and prepare for Pressure
test. See, Pressure testing and sterilization, (section 8).
7.7 Use
Following successful pressure testing and sterilization reconnect the Filtration Assembly to the
bioreactor (section 9)
XCellTM ATF System with C410:V4B Controller User Guide
58
8.0 Sterilization
WARNING:
These procedures refer to steam sterilization procedures. Steam is supplied at high pressure
and at high temperature, over 100ºC and can exceed 125ºC. All parts of the Filtration
Assembly are rapidly heated. Use similar precautions after removal of a system from an
autoclave. Such heated systems should only be handled by qualified personnel taking all
proper safety precautions.
8.1 Preparation of Filtration Assembly for Autoclaving
Repligen recommends sterilization of the Filtration Assembly by autoclaving. An appropriately sized
autoclave is required. Contact Repligen for dimensional analysis of the autoclave. Sterilization of the
Filtration Assembly by autoclaving is one of the simplest methods to sterilize the system. In addition
to the procedure below, please refer to the “XCell™ ATF System Filter Preparation and Autoclave
Guide” for further details.
Pre-Autoclaving check list:
8.1.1 Thoroughly wet the HFM with appropriate wetting agent
8.1.2 Fully 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, formation of pressure gradients across the
hollow fibers membranes during sterilization is minimized. This assures free flow of steam into
the unit and unobstructed pressure equilibration between all compartments within the unit;
particularly, the filtrate and retentate sides are at the same pressure during the sterilization and
cool down procedures.
Note: Use high capacity vent filters to allow unobstructed high flow of steam into and from the
system.
XCellTM ATF System with C410:V4B Controller User Guide
59
Figure 9: Filtration Assembly Prepared for Autoclaving
8.1.5 Close all unprotected ports.
8.1.6 Depending on the size/configuration of the autoclave, the Filtration Assembly can be placed
inside the autoclave either vertically or at an angle if necessary. Most autoclaves are not
sufficiently tall for vertical placement.
8.1.7 Use caution during the procedure so not to damage attached parts or tubing. Avoid kinking
or stressing attached tubing.
8.2 Autoclave Cycle
8.2.1 The Xcell ATF systems have been designed to be sterilized using an autoclave.
The XCell ATF System Filter Preparation and Autoclave Guide provides detailed
guidance on the entire procedure including the recommended filter integrity test
procedures and specifications. The features of the recommended cycle are intended
to ensure that the system will be effectively sterilized and that there is minimal
thermal stress imposed on the hollow fiber cartridge that could lead to integrity
failures.
XCellTM ATF System with C410:V4B Controller User Guide
60
The recommended cycle will require custom programming to incorporate a 90
minute preheat and 2-3 moderated prevac pulses to control the rate of temperature
change within the cartridge to a rate of 1°C/min during the warm up. Repligen
recommends that during the cycle development, several thermocouples should be
positioned within the assembly to track the rate of temperature change and confirm
that all positions are at 121-123°C for the duration of the sterilization section of the
cycle.
8.2.2 While autoclave conditions may vary based on requirements, the following are typical
autoclave conditions for the Filtration Assembly. Please refer to the XCell™ ATF System
Filter Preparation and Autoclave Guide for more details. The entire cycle may take 4-5
hours.
• The assembly should be placed in the autoclave at a 45° angle and be allowed to
warm up for a period not less than 60 minutes with steam in the jacket, but not
in the chamber.
• The active cycle will begin with a 5-minute purge where steam flows through the
autoclave directly to the drain with minimal increase in chamber pressure.
• Secondly, there are 2-3 vacuum pulses with “hold” periods in between. These
are critical to evacuate all of the air within the assembly and ensure that there is
a uniform temperature throughout the assembly prior to engaging the ramp up
to reach the sterilization temperature.
• Follow with a 1-minute steam purge to about 6psi, and 108 °C
• Ramp up slowly, 1C/min, to sterilization temperature / pressure, of 121 °C - 123 °C /
16psi
• Sterilize for ~ 55-60 min.
• Ramp down slowly, with wet cycle exhaust protocol or 0.5-1 ° C/min to 100o °C
• Allow the system to cool to 50 °C before handling
8.2.3 Open autoclave door, inspect the system, re-tighten all clamps (about ¼ turn).
8.2.4 Carefully remove the Filtration Assembly from the autoclave.
8.2.5 Preferably, remove the Filtration Assembly from autoclave into clean area.
8.2.6 Allow system to cool to room temperature in a clean area.
8.2.7 Pressurize system to about 5psi using sterile air source through one of the retentate
vent filters. This step is optional.
8.2.9 After cooling down to room temp or after pressurization of system, close all valves.
1.2.10 The system may be stored until use.
8.3 Sterilization of Filtrate / Harvest line
The Filtrate / Harvest line with end filter will be sterile following autoclave. One must assure
however that the Harvest line has been prepared with the appropriate tubing for use with
the filtrate / harvest pump. One may also prepare the Filtrate / Harvest line, post
autoclaving, using a tube welder. If a tube welder cannot be used, a disposable sterile
coupling may be used.
XCellTM ATF System with C410:V4B Controller User Guide
61
9.0 Connection to Bioreactor (ATF-to-Bioreactor)
Two types of connections between Filtration Assembly and bioreactor are commonly available.
• Hard connection that can be sterilized by SIP
• Soft connection that use single use connectors such as the Kleenpak, AseptiQuik, Opta,
Readymate DAC, Pure-Fit, or other connectors now available from various vendors.
9.1 Hard Connection
The user should verify the following procedure:
• Typically used with stainless steel bioreactor systems where steam is readily available.
• This connection consists of at least two isolation bivalves (Figure 1). One bivalve
attached to the vessel and the second bivalve attached to the Filtration Assembly.
• A flexible hose between the main branches of the two valves.
• Steam inlet- The side valve on one of the bivalves may be used for steam inlet.
• Condensate-The side valve on the other bivalve is used for drain condensate. This valve
should be the low point valve to assure complete condensate drainage. Attach a steam
trap to this valve and connect to a drain
• Close both Steam inlet and Condensate valves.
• Securely connect a regulated steam source to the steam inlet valve.
• Open steam service.
• Slowly open steam inlet valve.
• Slowly open steam condensate valve.
• Sterilize connection for about 20min. at 1210 C and ~16psi
• Cool-down.
• Close the Condensate valve.
• Rapidly close 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 connection post SIP will
generate a vacuum within the connection, which must be minimized.
XCellTM ATF System with C410:V4B Controller User Guide
62
10.0 Maintenance
10.1 Diaphragm
It is recommended that a new diaphragm be used with each new run. To avoid premature failure, it
is important to ensure that the diaphragm is seated in the proper orientation.
Use with aqueous liquids only. For use with other fluids contact Repligen for a technical discussion.
When used as instructed in this manual, the diaphragm is designed to last over 500,000 cycles.
10.2 Pump Air Inlet Filter
The replacement of the pump air inlet filter will be determined by how the system is configured. If
the air filter is autoclaved with the Filtration Assembly, it is qualified for 135°C, for 30 minutes, 3
times.
10.3 “O” Rings, gaskets and Quick Connects
The O-rings on the ventilation ports and quick connects (XCell™ ATF 4 System and XCell™
ATF 6 System) should be replaced every two or three runs. Replacement kits are available
from Repligen. HFM Filter “O” rings should be replaced with each new filter. For pump line,
air supply, and vacuum source, all “O” rings and gaskets should be replaced periodically. An
approved lubricant may be used to facilitate coupling of parts containing an “O” ring seal.
XCellTM ATF System with C410:V4B Controller User Guide
63
Appendix 1: Cycle time vs. Flow rate
XCell™ ATF System
PUMP VOLUME (L)
XCell™ ATF 4
&4MC
0.4
XCell™ ATF 6
1.3
XCell™ ATF
10
5.1
XCell™ ATF
10H
6.0
Cycle time (sec)
FLOW RATE (L/MIN)
4
6.0
18.8
76.5
90.0
6
4.0
12.5
51.0
60.0
8
3.0
9.4
38.3
45.0
10
2.4
7.5
30.6
36.0
12
2.0
6.3
25.5
30.0
14
1.7
5.4
21.9
25.7
16
1.5
4.7
19.1
22.5
18
1.3
4.2
17.0
20.0
20
1.2
3.8
15.3
18.0
XCellTM ATF System with C410:V4B Controller User Guide
64
Appendix 2: Access levels to the C410v4B controller
There are 3 User levels. Most restrictive are Operators, then Engineers and finally
Administrators. In general:
1. Operators have access to all functions except Algorithm review, Set Up and
Administration. Operators and higher can start and stop ATF pumping.
2. Engineers have access to all functions except Administration. Engineers and higher can
set flow set points, silence alarms [however, cannot remove alarms from the alarm list]
3. Administrators have unlimited access to all functions.
User Level
Screen
Controller Function
Parameter
Permissions
Operator
Main
General Access
General
Access Upon Login
Start/Stop
General Allowed
Allowed
Remote/Local
Toggle
Allowed
PFlow Status
LMP SP
Not Allowed
LPM PV
View only
Sec Calculated
View Only
Sec Actual
View Only
E Flow Status
LPM SP
Not Allowed
LPM PV
View Only
Sec Calculated
View Only
Sec Actual
View Only
P2 Trends
Enable
View Only(change range
in trends)
PV1
Input value
Not Allowed
PRV1
Input value
Not Allowed
PV2
Input value
Not Allowed
PRV2
Input value
Not Allowed
P2
General
View only
Bioreactor
View
Display only
Batch
View
Display only
Runtime
View
Display only
Current User
View
Display only
Alarms
View Only
General
Allowed
Silence Alarm
General
Not Allowed
Clear Alarm
General
Not Allowed
Trending
Process Trend
General
View and allowed to
adjust Min and Max
P2 Trend
General
View and allowed to
adjust Min and Max
PRV Trend
General
View and allowed to
adjust Min and Max
PV Trend
General
View and allowed to
adjust Min and Max
P3 Trend
General
View and allowed 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
XCellTM ATF System with C410:V4B Controller User Guide
65
User Level
Screen
Controller Function
Parameter
Permissions
Operator
Batch Info -
Overview
Batch Data
Name
View Only
Elapsed Time
View Only
Cycle Count
View Only
User ID
View Only
Batch Setup
Name
View Only
Reset
View Only
Batch Info –
Algorithm
General Access
General
No Access
Algorithm
Performance
Primary Method
No Access
Override Time
No Access
Overflow
No Access
Setup Up Basic
Controller Set up
Pump Model
No Access
Control Mode
No Access
Alarm Delay
No Access
Slope Function
Enabled
No Access
Bioreactor Pressure
No Access
Height Differential
No Access
Pump Parameters
Pressure Offset
No Access
Delay Time
No Access
Over Time
No Access
PV Step Size
No Access
Alarm Set Points
P2 Pressure
No Access
Alarm Delays
No Access
Set Up Advanced
User Set Point
Ranges
Pressure Cycle Flow
No Access
Pressure Cycle Flow
Max
No Access
Pressure Cycle Flow
Min
No Access
Exhaust Cycle Flow
Max
No Access
Exhaust Cycle Flow
Min
No Access
Output (CV) Limits
PV1(%)
No Access
PV2(%)
No Access
PRV1(psi)
No Access
PRV2(psi)
No Access
Accept Changes
No Access
Discard Changes
No Access
Set Up Calibration
General Access
View
No Access
Set Up Help
General Access
View Only
No Access
Admin
Basic
General Access
Not Allowed
Users
General Access
Not Allowed
XCellTM ATF System with C410:V4B Controller User Guide
66
User Level
Screen
Controller Function
Parameter
Permissions
Engineer
Main
General Access
General
Access Upon Login
Start/Stop
General Allowed
Allowed
Remote/Local
Toggle
Allowed
PFlow Status
LMP SP
Allowed to Change
LPM PV
View only
Sec Calculated
View Only
Sec Actual
View Only
E Flow Status
LPM SP
Allowed to Change
LPM PV
View Only
Sec Calculated
View Only
Sec Actual
View Only
P2 Trends
Enable
View Only (change
range in trends)
PV1
Input value
Allowed
PRV1
Input value
Allowed
PV2
Input value
Allowed
PRV2
Input value
Allowed
P2
General
View only
Bioreactor
View
Display only
Batch
View
Display only
Runtime
View
Display only
Current User
View
Display only
Alarms
View Only
General
Allowed
Silence Alarm
General
Allowed
Clear Alarm
General
Not Allowed
Trending
Process Trend
General
View and allowed to
adjust Min and Max
P2 Trend
General
View and allowed to
adjust Min and Max
PRV Trend
General
View and allowed to
adjust Min and Max
PV Trend
General
View and allowed to
adjust Min and Max
P3 Trend
General
View and allowed 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
XCellTM ATF System with C410:V4B Controller User Guide
67
User Level
Screen
Controller Function
Parameter
Permissions
Engineer
Batch Info -
Overview
Batch Data
Name
View Only
Elapsed Time
View Only
Cycle Count
View Only
User ID
View Only
Batch Setup
Name
Allowed to Change
Reset
Allowed
Batch Info –
Algorithm
General Access
View
Allowed
Algorithm
Performance
Reset
Allowed
Setup Up Basic
Controller Set up
Pump Model
Allowed to Change
Control Mode
Allowed to Change
Alarm Delay
Allowed to Change
Slope Function
Enabled
Allowed to Change
Bioreactor Pressure
Allowed to Change
Bioreactor Prefix
Allowed to Change
Height Differential
Allowed to Change
Pump Parameters
Pressure Offset
Allowed to Change
Delay Time
Allowed to Change
Over Time
Allowed to Change
PV Step Size
Allowed to Change
Alarm Set Points
P2 Pressure
Allowed to Change
Alarm Delays
Allowed to Change
Set Up Advanced
User Set Point
Ranges
Pressure Cycle Flow
Allowed to Change
Pressure Cycle Flow
Max
Allowed to Change
Pressure Cycle Flow
Min
Allowed to Change
Exhaust Cycle Flow
Max
Allowed to Change
Exhaust Cycle Flow
Min
Allowed to Change
Output (CV) Limits
PV1(%)
Allowed to Change
PV2(%)
Allowed to Change
PRV1(psi)
Allowed to Change
PRV2(psi)
Allowed to Change
Accept Changes
Allowed to Change
Discard Changes
Allowed to Change
Set Up Calibration
General Access
View
Allowed
Calibrate
Select
Allowed
Reference Value
Input Value
Allowed
Accept Calibration
General
Allowed
PV1
Input value
Allowed
PRV1
Input value
Allowed
PV2
Input value
Allowed
PRV2
Input value
Allowed
P2
General
View only
Engineer
Set Up Calibration
Solenoid
Toggle
Allowed
Set Up Help
General Access
View Only
Allowed
Admin
Basic
General Access
Not Allowed
Admin
Users
General Access
Not Allowed
XCellTM ATF System with C410:V4B Controller User Guide
68
User Level
Screen
Controller Function
Parameter
Permissions
Administrator
Main
General Access
General
Access Upon Login
Start/Stop
General Allowed
Allowed
Remote/Local
Toggle
Allowed
PFlow Status
LMP SP
Allowed to Change
LPM PV
View only
Sec Calculated
View Only
Sec Actual
View Only
E Flow Status
LPM SP
Allowed to Change
LPM PV
View Only
Sec Calculated
View Only
Sec Actual
View Only
P2 Trends
Enable
View Only(change
range in trends)
PV1
Input value
Allowed
PRV1
Input value
Allowed
PV2
Input value
Allowed
PRV2
Input value
Allowed
P2
General
View only
Bioreactor
View
Display only
Batch
View
Display only
Runtime
View
Display only
Current User
View
Display only
Alarms
View Only
General
Allowed
Silence Alarm
General
Allowed
Clear Alarm
General
Allowed
Trending
Process Trend
General
View and allowed
to adjust Min and
Max
P2 Trend
General
View and allowed
to adjust Min and
Max
PRV Trend
General
View and allowed
to adjust Min and
Max
PV Trend
General
View and allowed
to adjust Min and
Max
P3 Trend
General
View and allowed
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
Administrator
Batch Info -
Overview
Batch Data
Name
View Only
Elapsed Time
View Only
Cycle Count
View Only
XCellTM ATF System with C410:V4B Controller User Guide
69
User Level
Screen
Controller Function
Parameter
Permissions
User ID
View Only
Batch Setup
Name
Allowed to Change
Reset
Allowed
Batch Info –
Algorithm
General Access
View
Allowed
Algorithm
Performance
Reset
Allowed
Setup Up Basic
Controller Set up
Pump Model
Allowed to Change
Control Mode
Allowed to Change
Alarm Delay
Allowed to Change
Slope Function
Enabled
Allowed to Change
Bioreactor Pressure
Allowed to Change
Bioreactor Prefix
Allowed to Change
Height Differential
Allowed to Change
Pump Parameters
Pressure Offset
Allowed to Change
Delay Time
Allowed to Change
Over Time
Allowed to Change
PV Step Size
Allowed to Change
Alarm Set Points
P2 Pressure
Allowed to Change
Alarm Delays
Allowed to Change
Set Up Advanced
User Set Point
Ranges
Pressure Cycle Flow
Allowed to Change
Pressure Cycle Flow
Max
Allowed to Change
Pressure Cycle Flow
Min
Allowed to Change
Exhaust Cycle Flow
Max
Allowed to Change
Exhaust Cycle Flow
Min
Allowed to Change
Output (CV) Limits
PV1(%)
Allowed to Change
PV2(%)
Allowed to Change
PRV1(psi)
Allowed to Change
PRV2(psi)
Allowed to Change
Accept Changes
Allowed to Change
Discard Changes
Allowed to Change
Set Up Calibration
General Access
View
Allowed
Calibrate
Select
Allowed
Reference Value
Input Value
Allowed
Accept Calibration
General
Allowed
PV1
Input value
Allowed
PRV1
Input value
Allowed
PV2
Input value
Allowed
PRV2
Input value
Allowed
P2
General
View only
Solenoid
Toggle
Allowed
Administrator
Set Up Help
General Access
View Only
Allowed
Admin - Basic
General Access
General Access
Allowed
No. of Pump Cycles
Reset
Allowed
Sol. Force
Off/On
Allowed
Close Application
Access
Allowed
PLC status
PLC run/stop
Allowed
No. of Pump Cycles
Reset
Allowed
XCellTM ATF System with C410:V4B Controller User Guide
70
User Level
Screen
Controller Function
Parameter
Permissions
Sol. Force
Off/On
Allowed
Clean Screen
Access
Allowed
Date/Time
Input Value
Allowed
Pressure Units
Toggle PSI/Bar
Allowed (when in
local mode)
Logon Splash
Toggle
Allowed
Profibus 1
Access
Allowed
Profibus 2
Access
Allowed
Profinet
Access
Allowed
Admin - Users
General Access
General Access
Allowed
User Password/
Maintenance
User
Allowed for all
except Admin and
PLC User
Password
Allowed for all
except for PLC User
Group
Allowed for all but
Unauthorized
Logoff time
Allowed
XCellTM ATF System with C410:V4B Controller User Guide
71
Appendix 3: Controller Lists: Alarm, Warning, Inputs & Outputs
Alarms/Warning List
Tag Name
Description
Alarm
Enable
Condition
Delay
Action
"DB1".ALARM_REG(0)
XCell™ ATF
Warning condition
has not been reset
within the alarm
delay time, XCell™
ATF function halted.
Pump is
Running and
Alarm Delay
Timer Setpoint
is Greater than
Zero.
*See Note
Number of
minute(s).
Determined by
Alarm Delay
parameter on
Basic Set Up
Screen
Alarm,
System Stop,
Activate System
Fault Warning Horn
"DB1".ALARM_REG(1)
Main Power Loss
(120/220) while
Pump was running
First Scan of
PLC on Power
Up.
On first scan Pump
State is not 0
N/A
Alarm,
System Stop,
Activate System
Fault Warning Horn
"DB1".ALARM_REG(2)
P2 Pressure Above
HI HI Limit
Pump is
Running
P2 pressure is
greater than or
equal to the P2 Hi
HI Pressure alarm
setpoint.
P2 Hi Hi Set
Point Alarm
Delay in 10ms
increments.
Alarm,
System Stop,
Activate System
Fault Warning Horn
"DB1".WARN_REG(0)
Flow Set Point
cannot be reached.
P-Flow Regulator
(PV1) above
maximum operating
setting
Pump is
Running
PV1 >= PV1MAX
N/A
Warning,
Activate System
Fault Warning Horn
"DB1".WARN_REG(1)
Flow Set Point
cannot be reached.
P-Flow Regulator
(PV1) below
minimum operating
setting
Pump is
Running
PV1 <= PV1MIN
N/A
Warning,
Activate System
Fault Warning Horn
"DB1".WARN_REG(2)
Exhaust Set Point
cannot be reached.
E-Flow Regulator
(PV2) above
maximum operating
setting
Pump is
Running
PV2 >= PV2MAX
N/A
Warning,
Activate System
Fault Warning Horn
"DB1".WARN_REG(3)
Exhaust Set Point
cannot be reached.
E-Regulator (PV2)
below minimum
operating setting
Pump is
Running
PV2 <= PV2MIN
N/A
Warning,
Activate System
Fault Warning Horn
"DB1".WARN_REG(4)
P2 Pressure below
Lo Lo Limit
Pump is
Running
P2_PV <=
Pressure Alarm Lo
Lo Setpoint
P2 Lo Lo Set
Point Alarm
Delay in 10ms
increments.
Warning,
Activate System
Fault Warning Horn
"DB1".WARN_REG(5)
System Stop
Pressed
Always
A Blue system stop
buttons are
pressed
N/A
Warning, Activate
System Fault
Warning
*NOTE: "DB1".WARN_REG(0) is true, or "DB1".WARN_REG(1) is true, or "DB1".WARN_REG(2) is true, or
"DB1".WARN_REG(3) is true, or "DB1".WARN_REG(4) is true.
XCellTM ATF System with C410:V4B Controller User Guide
72
Input/ Output List
Tag Name
Description
PLC Tag Address
Engineering
Valve Fail
Position
Real Time
Trend
Range
Decimal Places
Units
PP1
System Stop
%I0.0
N/A
N/A
N/A
N/A
N/A
PP2
System Stop
%I0.1
N/A
N/A
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 - 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 - 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 - 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
-
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 - 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/Deflate Solenoid
%Q0.2
N/A
N/A
N/A
N/A
N/A
CR1
Pump Controller Status Relay
#1
%Q0.3
N/A
N/A
N/A
N/A
N/A
CR2
Pump Controller Status Relay
#2
%Q0.4
N/A
N/A
N/A
N/A
N/A
CR3
Pump Interlock Relay #3
%Q0.5
N/A
N/A
N/A
N/A
N/A
CR4
Pump Interlock Relay #4
%Q0.6
N/A
N/A
N/A
N/A
N/A
PL2
System Stop Indicator
%Q0.7
N/A
N/A
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 - Spare
N/A
N/A
N/A
N/A
N/A
N/A
RAW_P2_PV_1
Pump Pressure
%IW96
Note 1
1
PSI
N/A
Y
-44.7
RAW_PRV1_PV_1
Inflation Pressure
%IW98
Note 1
1
PSI
N/A
Y
0 - 40
RAW_PRV2_PV_1
Deflation Pressure
%IW100
Note 1
1
PSI
N/A
Y
-15
RAW_AIW10_PV_1
Spare
N/A
N/A
N/A
N/A
N/A
N/A
RAW_P3_PV_1
Optional Pressure 3
%IW104
Note 1
N/A
PSI
N/A Y RAW_P4_PV_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_1
Inflation Pressure
%QW128
0-100 1 %
FC Y RAW_PRV2_CV_1
Deflation Pressure
%QW130
0-100 1 %
FO
Y
RAW_PV1_CV_1
Inflation Pressure Proportional
%QW132
0 - 40 1 PSI
N/A
Y
RAW_PV2_CV_1
Deflation Pressure Proportional
%QW134
-15
1
PSI
N/A
Y
Note 1: Depends on calibration
XCellTM ATF System with C410:V4B Controller User Guide
73
Appendix 4: Profinet Communication
C410 v4B Profinet® Set-up and Connectivity
Profinet® Infrastructure
The communication link between the Windows environment and the XCell™ ATF Controller is
based on Profinet®. Profinet® is an open Industrial Ethernet standard developed by the
PROFIBUS Organization and is standard Ethernet (IEEE 802.3). The Profinet® communication
protocol sends and receives data using the open Ethernet TCP/IP standard at a bandwidth of
100 Mbit/s and functions identical to traditional industrial Ethernet in providing “real-time”
channel for time-critical communications (i.e. process data)
Configuration
The communications interface between the controller HMI and PLC is based on Profinet
(Industrial Ethernet). The controller is factory set to the following IP settings:
IP Address
Subnet Mask
Default Gateway
HMI
192.168.1.167
255.255.255.0
None
PLC
192.168.1.168
255.255.255.0
None
This factory default setting has the HMI and PLC on the same subnet allowing proper
communications to take place. If ‘####’ appears in input fields and the software version is not
displayed on the administration screen, the HMI and PLC may not be properly connected and
the connection may need to be reset. See below for instructions on how to set IP Addresses
and connections.
XCellTM ATF System with C410:V4B Controller User Guide
74
Set/Change IP Address of HMI
1. HMI IP Address setting:
a. Select settings from the start menu, select network and dial up connections, then
select PN_X1.
b. From this interface, the IP Address, Subnet Mask and all other Ethernet Properties
can be adjusted.
2. PLC IP Address setting:
c. Select settings from the start menu (or go back to the setting screen) and select
Service & Commissioning.
d. Select IP config by pressing the right arrow to reveal the 5th tab.
e. From the Service & Commissioning screen, press the assign IP button.
f. On the following screen select network, scan and start. “Scan is running” appears at
the bottom of the window.
g. After the scan is complete, the S7-1200 device should appear. Select the S7-1200
device 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, select device, download and IP to assign the
address to the device. “IP suite settings could be assigned” appears at the bottom of
the window.
j. Exit out of the assign IP
3. Set Connection between HMI and PLC:
k. From the Service & Commissioning screen, press the set connection button.
l. On the following screen press the Find Online button. After the scan is complete,
the S7-1200 device should appear. Select it, and the IP Address box below contains
the PLC’s address. Note: It can also be entered manually.
m. Press OK to accept and close the window.
n. Press Save to set the connection. “Save is successful” appears at the bottom of the
window.
o. Close the window to exit.
p. Close the Service & Commissioning window.
q. Close the Settings Window
4. Start the program again and ensure that ‘####’ do not appear in the main screen fields.
XCellTM ATF System with C410:V4B Controller User Guide
75
Appendix 5: Profibus Communication
The XCell™ ATF C410v4 controller is capable of remote operation using a Profibus DP slave card that
enables communication to the Profibus DP master (customer). To activate this control mode, the
selector switch on the Administrator screen must be toggled to Profibus. See section F.2 Basic
Administration Screen (Remote Mode Connection) selector switch.
1.1 Remote Control Mode
It is possible to set the XCell™ ATF to Remote Control Mode from the main screen. With the
control mode set to “Remote”, the XCell™ ATF uses parameters sent from the Profibus master.
When set to “Local” parameters may be entered from the local Human Machine Interface.
Instead of using the onboard HMI (operator interface), the Remote control mode is intended to
allow another operator interface (provided by the end user) to control ATF functions, as well as
receive feedback from the ATF controller regarding the ATF status and data acquisition for
historical purposes.
1.2 Input Signals (from Master to XCell™ ATF)
The master, a system with a PROFIBUS interface, for example, sends output data to a slave
device (XCell™ ATF) in its configuration, which becomes input for the XCell™ ATF controller. The
input signals from Master to XCell™ ATF are divided into different pages. The master has to set
a parameter to define which of the pages is being sent, using the ‘SendingDataPage’ parameter
(InputPage0, InputPage1, InputPage2, InputPage3, InputPage4). When the XCell™ ATF receives
a new value in “SendingDataPage” from the Master, a timer is started. After 500ms, the XCell
ATF controller begins copying the values from the Profibus input to the parameters defined in
“Input Signals (from Master to XCell™ ATF)” tables (provided the system is in remote control
mode and the selector switch is set to Profibus)
Should a parameter (from the master) be changed without changing page, the value is copied
immediately.
When programming commands to the ATF controller, it is recommended that
“SendingDataPage” value remain at the value of the most recently sent command page, until an
operator interacts with the master’s user interface, requesting a change to the ATF controller’s
state. Examples include: Remote setup, Remote Start, Remote Stop as discussed below.
Further, it is recommended to set the “SendingDataPage” value to 3 or 4 (for infrequent
calibration commands) only when ATF is not running, and Repligen service personnel
specifically are required to perform calibration activities.
1.3 Output Signals (to Master from XCell™ ATF)
The slave device (XCell™ ATF) provides output data, which becomes inputs for the master. The
output signals from the ATF are divided into different pages. The master has to set a parameter
to define which of the pages is to be received, using the ‘RequestedDataPage’ parameter
(OutputPage0, OutputPage1, OutputPage2, OutputPage3, OutputPage4). When the XCell™ ATF
receives a new value in “RequestedDataPage” from the Master, the XCell ATF controller begins
copying the values from the parameters defined in “Output Signals (from XCell™ ATF to
Master)” tables to the Profibus outputs.
The Master can continuously cycle (in a recommended 1 second interval) the
RequestedDataPage parameter to receive all the output data from the XCell™ ATF. The
XCellTM ATF System with C410:V4B Controller User Guide
76
ActiveDataPage and ATF_Heartbeat are provided on every output page, so the Master can
continually monitor the communication integrity and verify the data page being provided.
Profibus Configuration for DCS Integration
The XCell™ ATFC410v4 controller is configured as a slave Profibus node; at node address 2
(default). The Siemens CM-1242-5 Profibus DP slave module’s baud-rate is detected
automatically when connected to the DP network. It is configured not to exceed 1.5 Mbps and
is tested at 187.5 kbps.
Profibus address can be changed from the HMI Admin screen (For HMI-enabled units only,
black-box configured controller Profibus address is set at the factory). ProfiBus1 & Profibus2
options on the HMI display Profibus values in the PLC which can be accessed remotely. See
Section 6.3 (F2) for details.
Black-Box Configuration
Black-box configuration is similar to remote control mode but allows completely remote
operation of the XCell™ ATF system with HMI disabled at the factory. Black-box configuration
can be requested at time of ordering a new system.
Prerequisites
The XCell™ ATF should be calibrated and connected to a Bioreactor or other vessel.
The XCell™ ATF should be in a Remote Control Mode.
Remote Set-up
The master sends input parameters pages 1 and 2 to XCell™ ATF or set up the parameters
locally. The Start/Stop parameter should be “0”.
Remote Start
The master sends analog input parameters page 0 to XCell™ ATF. Initially, the Start/Stop bit
should be reset to “0”.
The master starts the filtration by setting the Start/Stop bit to “1”. It is recommended that
unless operator intervention is required, “SendingDataPage” should remain at 0.
Remote Stop
The master stops the filtration by resetting the Start/Stop bit to “0”. The ATF stops running. It
is recommended that unless operator intervention is required, “SendingDataPage” should
remain at 0.
Remote running
During a run it is possible to change all parameters remotely.
If the XCell™ ATF is changed from Remote Control Mode to Local Control Mode, it continues to
run, and it is possible to stop the run from the HMI. If the filtration has been stopped locally
and then changed back to Remote Control Mode it will not restart. To restart the filtration the
master has to reset the Start/stop bit to 0 and then back to 1.
XCellTM ATF System with C410:V4B Controller User Guide
77
System-stop
If the XCell™ ATF is stopped by the System-stop (one of 2 blue buttons on either the P-Box or EBox), and the System-stop is reset, the XCell™ ATF will not restart until the master has to reset
Start/stop to 0 and then set back to 1. System-stop is indicated visually with the buttons
illuminated and indicated via profibus by OutputPage0.System Stop Active (%DB31.DBX366.5)
Calibration Process
When not running, calibration activities can be performed.
The master sends input parameters pages 3 and 4 to XCell™ ATF or calibrate locally. As in
Remote Set-up, the Start/Stop parameter needs to be “0”.
Repligen recommends having a service technician perform calibration activities. Once loop
calibration is initiated, it must complete the calibration process. There is currently no means to
disable an enabled calibration without completing the process via remote commands.
Only one input loop shall be calibrated at a time. Each loop shall be calibrated in its entirety by
itself, without enabling (or initiating) the calibration of another loop.
The process of calibration is a 2-point linear scaling process, where a technician first confirms all
required utilities, external pressure gauge and loop wiring is connected. The following steps are
performed:
1) An enable bit is momentarily asserted. Controller is enabled in calibration mode for a
particular analog input.
2) Pneumatic devices are set to produce a minimum setting. The pressure in the system
approaches the minimum value commanded. Pressure gauge reading is allowed to
stabilize.
3) The pressure gauge reading is provided to the controller. A minimum capture bit is
momentarily asserted.
4) Pneumatic devices are set to produce a maximum setting. The value on the pressure
gauge is allowed to stabilize.
5) The pressure gauge reading is provided to the controller. A maximum capture bit is
momentarily asserted.
6) Once both minimum and maximum points are captured, the linear scaling calculation
can be performed by the PLC. This calculation is initiated by setting an accept bit
(momentarily asserted). Controller performs the linear scaling calculation and resets
the controller’s internal calibration enable bit.
Calibration Example
Technician calibrates the P2 pressure sensor.
1) Assert enable bit:
a. Set “SendingDataPage” = 3
b. Set InputPage3.P2_Cal_Enable = 1 until the OutputPage4.P2_Cal_Enable bit is
received.
i. Wait for the “RequestedDataPage” to be equal to 4; since cycling through output
data pages is recommended.
ii. Examine OutputPage4.P2_Cal_Enable. When true…
c. Reset InputPage3.P2_Cal_Enable = 0.
d. Controller is enabled in calibration mode for P2 analog input.
XCellTM ATF System with C410:V4B Controller User Guide
78
2) Pneumatic devices are set to produce a minimum setting. (PV2=100%, PRV2=-5.00 PSI,
Solenoid=0 [vacuum])
a. While “SendingDataPage” is still equal to 3…
b. Set InputPage3.PV2_SP = 100 Confirmed by examining OutputPage2.PV2
c. Set InputPage3.PRV2_SP = -5 Confirmed by examining
OutputPage1.PRV2
d. Reset InputPage3.Force_Solenoid = 0 Confirmed by examining
OutputPage4.Solenoid_Forced
e. The pressure in the system approaches the minimum value commanded.
Pressure gauge reading is allowed to stabilize.
Note: OutputPage0.P2_PV and OutputPage0.PRV2_PV should be within ±0.5 PSIG of the value on the
external pressure gauge.
3) Pressure gauge reading is provided to the controller.
a. Programmer provides a data entry location for technician to enter the pressure
value.
b. While “SendingDataPage” is still equal to 3…
c. Set InputPage3. P2_P1_EU = the pressure value from the data entry location.
d. Set InputPage3.P2_P1_Capture = 1 until the OutputPage4.P2_P1_Caputured bit
is received.
i. Wait for the “RequestedDataPage” to be equal to 4; since cycling through
output data pages is recommended.
ii. Examine OutputPage4.P2_ P1_Capture. When true…
e. Reset InputPage3.P2_P1_Capture = 0; the minimum capture bit is momentarily
asserted.
4) Pneumatic devices are set to produce a maximum setting. (PV1=100%, PRV1=20.00 PSI,
Solenoid=1 [pressure or air])
a. While “SendingDataPage” is still equal to 3…
b. Set InputPage3.PV1_SP = 100 Confirmed by examining OutputPage1.PV1
c. Set InputPage3.PRV1_SP = 20 Confirmed by examining
OutputPage1.PRV1
d. Set InputPage3.Force_Solenoid = 1 Confirmed by examining
Outputpage4.Solenoid_Forced
e. The pressure in the system approaches the maximum value commanded.
Pressure gauge reading is allowed to stabilize.
Note: OutputPage0.P2_PV and OutputPage0.PRV1_PV should be within ±0.5 PSIG of the value on the
external pressure gauge.
5) Pressure gauge reading is provided to the controller.
a. Programmer provides another data entry location for technician to enter the
pressure value.
b. While “SendingDataPage” is still equal to 3…
c. Set InputPage3. P2_P2_EU = the pressure value from the data entry location.
XCellTM ATF System with C410:V4B Controller User Guide
79
d. Set InputPage3.P2_P2_Capture = 1 until the OutputPage4.P2_Cal_Enable bit is
received.
i. Wait for the “RequestedDataPage” to be equal to 4; since cycling through
output data pages is recommended.
ii. Examine OutputPage4.P2_ P2_Capture. When true…
e. Reset InputPage3.P2_P2_Capture = 0; the maximum capture bit is momentarily
asserted.
6) Assert accept bit:
a. While “SendingDataPage” is still equal to 3…
b. Set InputPage3.P2_Accept = 1 until the OutputPage4.P2_Accept bit is received.
i. Wait for the “RequestedDataPage” to be equal to 4; since cycling through
output data pages is recommended.
ii. Examine OutputPage4.P2_Accept. When true…
c. Reset InputPage3.P2_Accept = 0.
d. Controller performs the linear scaling calculation and resets the controller’s
internal calibration enable bit.
7) Clean up: After all calibration activities are complete, be sure to perform the following:
a. Reset parameters that were set during the calibration process.
b. Set “SendingDataPage” = 0 to prepare for next ATF run commands.
XCellTM ATF System with C410:V4B Controller User Guide
80
Profibus Input Signals (from Master to XCell™ ATF)
The following parameters can be sent from Profibus Master to command the XCell™ ATF.
Input Page 0
Profibus
Address
Tagname plc in DB31
PLC Address
Definition
Units
Data
type
Byte # Bit # Structure
Tagname in structure
0 0 InputPageX
PB_ATF_START_STOP
%DB31.DBX128.0
AFT Start/Stop
Byte 1
InputPageX
PB_ATF_Ack_Alarms
%DB31.DBX128.1
ATF Acknowledge Alarms
2 InputPageX
PB_Reset_Counters
%DB31.DBX128.2
Algorithm Performance Counters - Reset
3 InputPageX
PB_ATF_Control_Mode
%DB31.DBX128.3
Control Mode
4 InputPageX
PB_ATF_Slope_Enabled
%DB31.DBX128.4
Slope Function Enabled
5 %DB31.DBX128.5
6
%DB31.DBX128.6
7
%DB31.DBX128.7
1
InputPageX
RequestedDataPage
%DB31.DBW130
Requested Data Page
Int-16 2 3
InputPageX
SendingDataPage
%DB31.DBW132
Sending Data Page
Int-16 4 5
InputPage0
ATF_Connected_Bioreactor
%DB31.DBW134
ATF Connected Bioreactor
Int-16 6 7
InputPage0
SpareBytes1[0]
Byte 8 SpareBytes1[1]
Byte 9 SpareBytes1[2]
Byte
10
SpareBytes1[3]
Byte
11
SpareBytes1[4]
Byte
12
SpareBytes1[5]
Byte
13
SpareBytes1[6]
Byte
14 InputPage0
PFLOWSP
%DB31.DBD144
Pressure Flow Setpoint LPM
LPM
Real
15 16 17 18 InputPage0
PTIMESP
%DB31.DBD148
Pressure Flow Setpoint Time
SEC
Real
19 20 21 22 InputPage0
EFLOWSP
%DB31.DBD152
Exhaust Flow Setpoint LPM
LPM
Real
23 24 25 26 InputPage0
ETIMESP
%DB31.DBD156
Exhaust Flow Setpoint Time
SEC
Real
27 28 29 30 InputPage0
PRV1
%DB31.DBD160
Flow Regulator Setpoint
BAR/PSI
Real
31 32 33 34 InputPage0
PRV2
%DB31.DBD164
Exhaust Regulator Setpoint
BAR/PSI
Real
35 36 37 38 InputPage0
PV1
%DB31.DBD168
Flow Proportional Valve Setpoint
%
Real
39 40 41 42 InputPage0
PV2
%DB31.DBD172
Exhaust Proportional Valve Setpoint
%
Real
43 44 45 46 InputPage0
BatchName[0]
%DB31.DBB176
Batch Name
ASCII
47
BatchName[1]
%DB31.DBB177
ASCII
48
BatchName[2]
%DB31.DBB178
ASCII
49
BatchName[3]
%DB31.DBB179
ASCII
50
BatchName[4]
%DB31.DBB180
ASCII
51..63
Unused
XCellTM ATF System with C410:V4B Controller User Guide
81
Input Page 1
Profibus Address
Tagname plc in DB31
PLC Address
Definition
Units
Data type
Byte #
Bit #
Structure
Tagname in structure
0 0 InputPageX
PB_ATF_START_STOP
%DB31.DBX128.0
AFT 1=Start/0=Stop
Byte 1
InputPageX
PB_ATF_Ack_Alarms
%DB31.DBX128.1
ATF Acknowledge Alarms
2 InputPageX
PB_Reset_Counters
%DB31.DBX128.2
Algorithm Performance Counters - Reset
3 InputPageX
PB_ATF_Control_Mode
%DB31.DBX128.3
Control Mode
4 InputPageX
PB_ATF_Slope_Enabled
%DB31.DBX128.4
Slope Function Enabled
5 6 7 1 InputPageX
RequestedDataPage
%DB31.DBW130
Requested Data Page
Int-16
2 3 InputPageX
SendingDataPage
%DB31.DBW132
Sending Data Page
Int-16
4 5 InputPage1
Model_Num_HMI
%DB31.DBW194
ATF Model Number
Int-16
6
0=ATF4, 1=ATF4MC, 2=ATF6, 3=ATF10lgcy &
4=ATF10 7
InputPage1
WATSP
%DB31.DBW196
Warning / Alarm Timer SP
MIN
Int-16
8 9 InputPage1
Bioreactor_Backpressure
%DB31.DBD198
Bioreactor Pressure
BAR/PSI
Real
10 11 12 13 InputPage1
Height_Differential
%DB31.DBW202
Height Differential
CM
Int-16
14 15 InputPage1
FDFOFST
%DB31.DBD204
Flow Driving Force Offset for Switching
BAR/PSI
Real
16 17 18 19 InputPage1
Press_Cycle_Delay_Time_SP
%DB31.DBW208
Pressure Cycle Delay Time SP
%
Int-16
20 21 InputPage1
Press_Cycle_Over_Time_SP
%DB31.DBW210
Pressure Cycle Over Time SP
%
Int-16
22 23 InputPage1
Pres_Cycl_PV_Step_Size
%DB31.DBD212
Pressure Cycle - PV Step Size - %
%
Real
24 25 26 27 InputPage1
EDFOFST
%DB31.DBD216
Exhaust Driving Force Offset for switching
BAR/PSI
Real
28 29 30 31 InputPage1
Vac_Cycle_Delay_Time_SP
%DB31.DBW220
Vaccum Cycle Delay Time SP
%
Int-16
32 33 InputPage1
Vac_Cycle_Over_Time_SP
%DB31.DBW222
Vaccum Cycle Over Time SP
%
Int-16
34 35 InputPage1
Exhs_Cycl_PV_Step_Size
%DB31.DBD224
Exhaust Cycle - PV Step Size
%
Real
36 37 38 39 InputPage1
P2_Pressure_Alarm_Hi_Hi_SP
%DB31.DBD228
P2 - Alarm SP - High High
BAR/PSI
Real
40 41 42 43 InputPage1
P2_Alarm_Hi_Hi_TMR_SP
%DB31.DBW232
P2 - Alarm Delay SP - High High
10MSEC
Int-16
44 45 InputPage1
P2_Pressure_Alarm_Lo_Lo_SP
%DB31.DBD234
P2 - Alarm SP - Low Low
BAR/PSI
Real
46 47 48 49 InputPage1
P2_Alarm_Lo_Lo_TMR_SP
%DB31.DBW238
P2 - Alarm Delay SP - Low Low
10MSEC
Int-16
50 51 InputPage1
PFLOWMAXSP
%DB31.DBD240
Max Pressure Flow Setpoint
LPM
Real
52 53 54 55 InputPage1
PFLOWMINSP
%DB31.DBD244
Min Pressure Flow Setpoint
LPM
Real
56 57 58 59 InputPage1
EFLOWMAXSP
%DB31.DBD248
Max Exhaust Flow Setpoint
LPM
Real
60 61 62 63
Unused
XCellTM ATF System with C410:V4B Controller User Guide
82
Input Page 2
Profibus Address
Tagname plc in DB31
PLC Address
Definition
Units
Data type
Byte #
Bit #
Structure
Tagname in structure
0 0 InputPageX
PB_ATF_START_STOP
%DB31.DBX128.0
AFT 1=Start/0=Stop
Byte
1 InputPageX
PB_ATF_Ack_Alarms
%DB31.DBX128.1
ATF Acknowledge Alarms
2 InputPageX
PB_Reset_Counters
%DB31.DBX128.2
Algorithm Performance Counters - Reset
3 InputPageX
PB_ATF_Control_Mode
%DB31.DBX128.3
Control Mode 4
InputPageX
PB_ATF_Slope_Enabled
%DB31.DBX128.4
Slope Function Enabled
5 6 7 1 0 InputPageX
RequestedDataPage
%DB31.DBW130
Requested Data Page
Int-16
2 0 3 0 InputPageX
SendingDataPage
%DB31.DBW132
Sending Data Page
Int-16
4 0 5 InputPage2
EFLOWMINSP
%DB31.DBD252
Min Exhaust Flow Setpoint
LPM
Real
6 7 8 9 InputPage2
PTIMEMAXSP
%DB31.DBD256
Max Pressure Flow Setpoint
SEC
Real
10 11 12 13 InputPage2
PTIMEMINSP
%DB31.DBD260
Min Pressure Flow Setpoint
SEC
Real
14 15 16 17 InputPage2
ETIMEMAXSP
%DB31.DBD264
Max Exhaust Flow Setpoint
SEC
Real
18 19 20 21 InputPage2
ETIMEMINSP
%DB31.DBD268
Min Exhaust Flow Setpoint
SEC
Real
22 23 24 25 InputPage2
PV1MAX
%DB31.DBD272
Flow Proportional Valve Max Value
%
Real
26 27 28 29 InputPage2
PV1MIN
%DB31.DBD276
Flow Proportional Valve Min Value
%
Real
30 31 32 33 InputPage2
PV2MAX
%DB31.DBD280
Exhaust Proportional Valve Max Value
%
Real
34 35 36 37 InputPage2
PV2MIN
%DB31.DBD284
Exhaust Proportional Valve Min Value
%
Real
38 39 40 41 InputPage2
PRV1MAX
%DB31.DBD288
Pressure Regulator Maximum Value
BAR/PSI
Real
42 43 44 45 InputPage2
PRV1MIN
%DB31.DBD292
Pressure Regulator Minimum Value
BAR/PSI
Real
46 47 48 49 InputPage2
PRV2MAX
%DB31.DBD296
Exhaust Regulator Maximum Value
BAR/PSI
Real
50
51
52 53 InputPage2
PRV2MIN
%DB31.DBD300
Exhaust Regulator Minimum Value
BAR/PSI
Real
54 55 56 57..63
Unused
XCellTM ATF System with C410:V4B Controller User Guide
83
Input Page 3
Profibus Address
Tagname plc in DB31
PLC Address
Definition
Units
Data type
Byte #
Bit #
Structure
Tagname in structure
0 0 InputPageX
P2_Cal_Enable
%DB31.DBX376.0
P2 Cal Select Button
Byte 1
InputPageX
PRV1_Cal_Enable
%DB31.DBX376.1
PRV1 Cal Select Button
2 InputPageX
PRV2_Cal_Enable
%DB31.DBX376.2
PRV2 Cal Select Button
3 InputPageX
P3_Cal_Enable
%DB31.DBX376.3
P3 Cal Select Button
4 InputPageX
P4_Cal_Enable
%DB31.DBX376.4
P4 Cal Select Button
5 6 7 1 InputPageX
RequestedDataPage
%DB31.DBW378
Requested Data Page
Int-16 2 3
InputPageX
SendingDataPage
%DB31.DBW380
Sending Data Page
Int-16 4 5
InputPage3
PV1_SP
%DB31.DBD382
PV1 Setpoint Value
%
Real 6 7 8 9
InputPage3
PV2_SP
%DB31.DBD386
PV2 Setpoint Value
%
Real
10 11 12 13 InputPage3
PRV1_SP
%DB31.DBD390
PRV1 Setpoint Value
PSI/Bar
Real
14 15 16 17 InputPage3
PRV2_SP
%DB31.DBD394
PRV2 Setpoint Value
PSI/Bar
Real
18 19 20 21 InputPage3
P2_P1_EU
%DB31.DBD398
P2 First Point Cal Engineering Units
PSI/Bar
Real
22 23 24 25 InputPage3
P2_P2_EU
%DB31.DBD402
P2 Second Point Cal Engineering Units
PSI/Bar
Real
26 27 28 29 InputPage3
PRV1_P1_EU
%DB31.DBD406
PRV1 First Point Cal Engineering Units
PSI/Bar
Real
30 31 32 33 InputPage3
PRV1_P2_EU
%DB31.DBD410
PRV1 Second Point Cal Engineering Units
PSI/Bar
Real
34 35 36 37 InputPage3
PRV2_P1_EU
%DB31.DBD414
PRV2 First Point Cal Engineering Units
PSI/Bar
Real
38 39 40 41 InputPage3
PRV2_P2_EU
%DB31.DBD418
PRV2 Second Point Cal Engineering Units
PSI/Bar
Real
42 43 44 45 InputPage3
P3_P1_EU
%DB31.DBD422
P3 First Point Cal Engineering Units
PSI/Bar
Real
46 47 48 49 InputPage3
P3_P2_EU
%DB31.DBD426
P3 Second Point Cal Engineering Units
PSI/Bar
Real
50
51
52 53 0 InputPage3
P2_P1_Capture
%DB31.DBD430.0
1 P2_P2_Capture
%DB31.DBD430.1
2 P2_Accept
%DB31.DBD430.2
3 PRV1_P1_Capture
%DB31.DBD430.3
4 PRV1_P2_Capture
%DB31.DBD430.4
5 PRV1_Accept
%DB31.DBD430.5
6 PRV2_P1_Capture
%DB31.DBD430.6
7 PRV2_P2_Capture
%DB31.DBD430.7
54 0 InputPage3
PRV2_Accept
%DB31.DBD431.0
1 P3_P1_Capture
%DB31.DBD431.1
2 P3_P2_Capture
%DB31.DBD431.2
3 P3_Accept
%DB31.DBD431.3
XCellTM ATF System with C410:V4B Controller User Guide
84
Input Page 3 (Continued)
Profibus Address
Tagname plc in DB31
PLC Address
Definition
Units
Data type
Byte #
Bit #
Structure
Tagname in structure
54 4
Force_Solenoid
%DB31.DBD431.4
5 6 7
55..63
Unused
XCellTM ATF System with C410:V4B Controller User Guide
85
Input Page 4
Profibus Address
Tagname plc in DB31
PLC Address
Definition
Units
Data type
Byte #
Bit #
Structure
Tagname in structure
0 0 InputPageX
P2_Cal_Enable
%DB31.DBX432.0
P2 Cal Select Button
Byte 1
InputPageX
PRV1_Cal_Enable
%DB31.DBX432.1
PRV1 Cal Select Button
2 InputPageX
PRV2_Cal_Enable
%DB31.DBX432.2
PRV2 Cal Select Button
3 InputPageX
P3_Cal_Enable
%DB31.DBX432.3
P3 Cal Select Button
4 InputPageX
P4_Cal_Enable
%DB31.DBX432.4
P4 Cal Select Button
5 6 7 1 InputPageX
RequestedDataPage
%DB31.DBW434
Requested Data Page
Int-16 2 3
InputPageX
SendingDataPage
%DB31.DBW436
Sending Data Page
Int-16 4 5
InputPage4
PV1_SP
%DB31.DBD438
PV1 Setpoint Value
%
Real 6 7 8 9
InputPage4
PV2_SP
%DB31.DBD442
PV2 Setpoint Value
%
Real
10 11 12 13 InputPage4
PRV1_SP
%DB31.DBD446
PRV1 Setpoint Value
PSI/Bar
Real
14 15 16 17 InputPage4
PRV2_SP
%DB31.DBD450
PRV2 Setpoint Value
PSI/Bar
Real
18 19 20 21 InputPage4
P4_P1_EU
%DB31.DBD454
P4 First Point Cal Engineering Units
PSI/Bar
Real
22 23 24 25 InputPage4
P4_P2_EU
%DB31.DBD458
P4 Second Point Cal Engineering Units
PSI/Bar
Real
26 27 28 29 InputPage4
P5_P1_EU
%DB31.DBD462
P5 First Point Cal Engineering Units
PSI/Bar
Real
30 31 32 33 InputPage4
P5_P2_EU
%DB31.DBD466
P5 Second Point Cal Engineering Units
PSI/Bar
Real
34 35 36 37 InputPage4
W1_P1_EU
%DB31.DBD470
W1 First Point Cal Engineering Units
PSI/Bar
Real
38 39 40 41 InputPage4
W1_P2_EU
%DB31.DBD474
W1 Second Point Cal Engineering Units
KG
Real
42 43 44 45 0 InputPage4
P4_P1_Capture
%DB31.DBD478.0
Byte 1
InputPage4
P4_P2_Capture
%DB31.DBD478.1
2
InputPage4
P4_Accept
%DB31.DBD478.2
3
InputPage4
P5_P1_Capture
%DB31.DBD478.3
4
InputPage4
P5_P2_Capture
%DB31.DBD478.4
5
InputPage4
P5_Accept
%DB31.DBD478.5
6
InputPage4
W1_P1_Capture
%DB31.DBD478.6
7
InputPage4
W1_P2_Capture
%DB31.DBD478.7
46 0 InputPage4
W1_Accept
%DB31.DBD479.0
Byte 1
InputPage4
Force_Solenoid
%DB31.DBD479.1
2
%DB31.DBD479.2
3
%DB31.DBD479.3
4
%DB31.DBD479.4
5
%DB31.DBD479.5
6
%DB31.DBD479.6
7
%DB31.DBD479.7
47 48 49
XCellTM ATF System with C410:V4B Controller User Guide
86
Input Page 4 (Continued)
Profibus Address
Tagname plc in DB31
PLC Address
Definition
Units
Data type
Byte #
Bit #
Structure
Tagname in structure
50 51 52 53 54 55..63
Unused
XCellTM ATF System with C410:V4B Controller User Guide
87
Profibus Output Signals (from XCell™ ATF to Master)
The following parameters can be read by the Profibus Master. The XCell™ ATF controller sends
parameters with the system in remote or local control mode. The heartbeat signal toggles every 1000ms.
Output Page 0
Profibus Address
Tagname plc in DB31
PLC Address
Definition
Units
Data type
Byte #
Bit #
Structure
Tagname in structure
0 OutputPageX
ActiveDataPage
%DB31.DBW310
Active Data Page
Int-16
1
2 0
OutputPageX
ATF_HeartBeat
%DB31.DBX312.0
ATF Heartbeat
Byte
1 OutputPageX
Rem_Profibus
%DB31.DBX312.1
ATF Remote Mode (Profibus)
2 OutputPageX
ATF_Trouble
%DB31.DBX312.2
ATF Common Trouble Alarm
3 OutputPageX
ATF_Running
%DB31.DBX312.3
ATF Run Status
4 OutputPageX
Pump_Alarm_0
%DB31.DBX312.4
Pump Alarm 5
OutputPageX
Pump_Alarm_1
%DB31.DBX312.5
Power Loss While Pump Running Alarm
6 OutputPageX
Pump_Alarm_2
%DB31.DBX312.6
P2 High High Pressure Alarm
7
3
OutputPage0
PFLOW
%DB31.DBD314
ATF Pressure Cycle Flow
LPM
Real
4
5 6 7
OutputPage0
PTIME
%DB31.DBD318
ATF Pressure Cycle Time
SEC
Real
8
9
10
11 OutputPage0
EFLOW
%DB31.DBD322
ATF Exhaust Cycle Flow
LPM
Real
12
13
14
15 OutputPage0
ETIME
%DB31.DBD326
ATF Exhaust Cycle Time
SEC
Real
16
17
18
19 OutputPage0
PV1
%DB31.DBD330
ATF Pressure Proportional Valve (PV1) Position
%
Real
20
21
22
23 OutputPage0
PV2
%DB31.DBD334
ATF Exhaust Proportional Valve (PV2) Position
%
Real
24
25
26
27 OutputPage0
PRV1_PV
%DB31.DBD338
ATF Pressure at PRV1
BAR/PSI
Real
28
29
30
31 OutputPage0
PRV2_PV
%DB31.DBD342
ATF Pressure at PRV2
BAR/PSI
Real
32
33
34
35 OutputPage0
P2_PV
%DB31.DBD346
ATF Pressure at P2
BAR/PSI
Real
36
37
38
39 OutputPage0
APC_PFlowPrimary
%DB31.DBW350
Algorithm Perfomance Counter - P-Flow - Primary
Int-16
40
41 OutputPage0
APC_PFlowOverride
%DB31.DBW352
Algorithm Perfomance Counter - P-Flow - Override
Int-16
42
43 OutputPage0
APC_PFlowOvertime
%DB31.DBW354
Algorithm Perfomance Counter - P-Flow - Overtime
Int-16
44
45 OutputPage0
APC_VFlowPrimary
%DB31.DBW356
Algorithm Perfomance Counter - V-Flow - Primary
Int-16
46
47 OutputPage0
APC_VFlowOverride
%DB31.DBW358
Algorithm Perfomance Counter - V-Flow - Override
Int-16
48
49 OutputPage0
APC_VFlowOvertime
%DB31.DBW360
Algorithm Perfomance Counter - V-Flow - Overtime
Int-16
50
51 OutputPage0
P3_PV
%DB31.DBD362
ATF Pressure at P3
BAR/PSI
Real
52
53
54
XCellTM ATF System with C410:V4B Controller User Guide
88
Output Page 0 (continued)
Profibus Address
Tagname plc in DB31
PLC Address
Definition
Units
Data type
Byte #
Bit #
Structure
Tagname in structure
55 0 OutputPage0
Warning_0
%DB31.DBX366.0
PV1>=PV1Max
Byte
1 OutputPage0
Warning_1
%DB31.DBX366.1
PV1<=PV1Min
2 OutputPage0
Warning_2
%DB31.DBX366.2
PV2>=PV2Max
3 OutputPage0
Warning_3
%DB31.DBX366.3
PV2<=PV2Min
4 OutputPage0
Warning_4
%DB31.DBX366.4
P2<=P2 Low Low Setpoint
5 OutputPage0
System Stop Active
%DB31.DBX366.5
Set when SS pressed, reset when ATF start or first scan
6 OutputPage0
%DB31.DBX366.6
7
OutputPage0
%DB31.DBX366.7
56 0 OutputPage0
PB_ATF_START_STOP
%DB31.DBX367.0
AFT Start/Stop
Byte
1 OutputPage0
PB_ATF_Ack_Alarms
%DB31.DBX367.1
ATF Acknowledge Alarms
2 OutputPage0
PB_Reset_Counters
%DB31.DBX367.2
Algorithm Performance Counters - Reset
3 OutputPage0
PB_ATF_Control_Mode
%DB31.DBX367.3
Control Mode
4 OutputPage0
PB_ATF_Slope_Enabled
%DB31.DBX367.4
Slope Function Enabled
5
%DB31.DBX367.5
6
%DB31.DBX367.6
7
%DB31.DBX367.7
57 OutputPage0
ATF_Connected_Bioreactor
%DB31.DBW368
ATF Connected Bioreactor
Int-16
58
59 OutputPage0
BatchName[0]
%DB31.DBB370
Batch Name
ASCII
60
BatchName[1]
%DB31.DBB371
ASCII
61
BatchName[2]
%DB31.DBB372
ASCII
62
BatchName[3]
%DB31.DBB373
ASCII
63
BatchName[4]
%DB31.DBB374
ASCII
XCellTM ATF System with C410:V4B Controller User Guide
89
Output Page 1
Profibus Address
Tagname plc in DB31
PLC Address
Definition
Units
Data type
Byte #
Bit #
Structure
Tagname in structure
0 OutputPageX
ActiveDataPage
%DB31.DBW310
Active Data Page
Int-16
1
2 0
OutputPageX
ATF_HeartBeat
%DB31.DBX312.0
ATF Heartbeat
Byte
1 OutputPageX
Rem_Profibus
%DB31.DBX312.1
ATF Remote Mode (Profibus)
2 OutputPageX
ATF_Trouble
%DB31.DBX312.2
ATF Common Trouble Alarm
3 OutputPageX
ATF_Running
%DB31.DBX312.3
ATF Run Status
4 OutputPageX
Pump_Alarm_0
%DB31.DBX312.4
Pump Alarm 5
OutputPageX
Pump_Alarm_1
%DB31.DBX312.5
Power Loss While Pump Running Alarm
6 OutputPageX
Pump_Alarm_2
%DB31.DBX312.6
P2 High High Pressure Alarm
7
3
OutputPage1
P2_PV
%DB31.DBD480
ATF Pressure at P2
PSI/Bar
Real
4
5 6 7
OutputPage1
PRV1_PV
%DB31.DBD484
ATF Pressure at PRV1
PSI/Bar
Real
8
9
10
11 OutputPage1
PRV2_PV
%DB31.DBD488
ATF Pressure at PRV2
PSI/Bar
Real
12
13
14
15 OutputPage1
P3_PV
%DB31.DBD492
ATF Pressure at P3
PSI/Bar
Real
16
17
18
19 OutputPage1
P4_PV
%DB31.DBD496
ATF Pressure at P4
PSI/Bar
Real
20
21
22
23 OutputPage1
P5_PV
%DB31.DBD500
ATF Pressure at P5
PSI/Bar
Real
24
25
26
27 OutputPage1
W1_PV
%DB31.DBD504
Force at Loadcell W1
KG
Real
28
29
30
31 0 OutputPage1
SOL_1
%DB31.DBD508.0
Turn On Solenoid 1
Byte
1
Bar_Mode
%DB31.DBD508.1
2 PSI_Mode
%DB31.DBD508.2
3 AIW04_Cal_Enable
%DB31.DBD508.3
4 AIW04_Cal_Accept_Vis
%DB31.DBD508.4
5 AIW06_Cal_Enable
%DB31.DBD508.5
6 AIW06_Cal_Accept_Vis
%DB31.DBD508.6
7 AIW08_Cal_Enable
%DB31.DBD508.7
XCellTM ATF System with C410:V4B Controller User Guide
90
Output Page 1 (Continued)
Profibus Address
Tagname plc in DB31
PLC Address
Definition
Units
Data type
Byte #
Bit #
Structure
Tagname in structure
32 0 OutputPage1
AIW08_Cal_Accept_Vis
%DB31.DBD509.0
1 AIW12_Cal_Enable
%DB31.DBD509.1
2 AIW12_Cal_Accept_Vis
%DB31.DBD509.2
3 AIW14_Cal_Enable
%DB31.DBD509.3
4 AIW14_Cal_Accept_Vis
%DB31.DBD509.4
5 AIW16_Cal_Enable
%DB31.DBD509.5
6 AIW16_Cal_Accept_Vis
%DB31.DBD509.6
7 AIW18_Cal_Enable
%DB31.DBD509.7
33 0 OutputPage1
AIW18_Cal_Accept_Vis
%DB31.DBD510.0
1
%DB31.DBD510.1
2
%DB31.DBD510.2
3
%DB31.DBD510.3
4
%DB31.DBD510.4
5
%DB31.DBD510.5
6
%DB31.DBD510.6
7
%DB31.DBD510.7
34
35 OutputPage1
PFLOWSP
%DB31.DBD512
Pressure Flow Setpoint LPM
LPM
Real
36
37
38
39 OutputPage1
PTIMESP
%DB31.DBD516
Pressure Flow Setpoint Time
SEC
Real
40
41
42
43 OutputPage1
EFLOWSP
%DB31.DBD520
Exhaust Flow Setpoint LPM
LPM
Real
44
45
46
47 OutputPage1
ETIMESP
%DB31.DBD524
Exhaust Flow Setpoint Time
SEC
Real
48
49
50
51 OutputPage1
PRV1
%DB31.DBD528
Flow Regulator Setpoint
BAR/PSI
Real
52
53
54
55 OutputPage1
PRV2
%DB31.DBD532
Exhaust Regulator Setpoint
BAR/PSI
Real
56
57
58
59 OutputPage1
PV1
%DB31.DBD536
Flow Proportional Valve Setpoint
%
Real
60
61
62
63
XCellTM ATF System with C410:V4B Controller User Guide
91
Output Page 2
Profibus Address
Tagname plc in DB31
PLC Address
Definition
Units
Data type
Byte #
Bit #
Structure
Tagname in structure
0 OutputPageX
ActiveDataPage
%DB31.DBW310
Active Data Page
Int-16 1
2 0 OutputPageX
ATF_HeartBeat
%DB31.DBX312.0
ATF Heartbeat
Byte
1 OutputPageX
Rem_Profibus
%DB31.DBX312.1
ATF Remote Mode (Profibus)
2 OutputPageX
ATF_Trouble
%DB31.DBX312.2
ATF Common Trouble Alarm
3 OutputPageX
ATF_Running
%DB31.DBX312.3
ATF Run Status 4
OutputPageX
Pump_Alarm_0
%DB31.DBX312.4
Pump Alarm 5
OutputPageX
Pump_Alarm_1
%DB31.DBX312.5
Power Loss While Pump Running Alarm
6 OutputPageX
Pump_Alarm_2
%DB31.DBX312.6
P2 High High Pressure Alarm
7
3
OutputPage2
PV2
%DB31.DBD542
Exhaust Proportional Valve Setpoint
%
Real 4 5 6 7
OutputPage2
Model_Num_HMI
%DB31.DBW546
ATF Model Number
Int-16 8 0=ATF4, 1=ATF4MC, 2=ATF6, 3=ATF10lgcy & 4=ATF10
9 OutputPage2
WATSP
%DB31.DBW548
Warning / Alarm Timer SP
MIN
Int-16
10
11 OutputPage2
Bioreactor_Backpressure
%DB31.DBD550
Bioreactor Pressure
BAR/PSI
Real
12
13
14
15 OutputPage2
Height_Differential
%DB31.DBW554
Height Differential
CM
Int-16
16
17 OutputPage2
FDFOFST
%DB31.DBD556
Flow Driving Force Offset for Switching
BAR/PSI
Real
18
19
20
21 OutputPage2
Press_Cycle_Delay_Time_SP
%DB31.DBW560
Pressure Cycle Delay Time SP
%
Int-16
22
23 OutputPage2
Press_Cycle_Over_Time_SP
%DB31.DBW562
Pressure Cycle Over Time SP
%
Int-16
24
25 OutputPage2
Pres_Cycl_PV_Step_Size
%DB31.DBD564
Pressure Cycle - PV Step Size - %
%
Real
26
27
28
29 OutputPage2
EDFOFST
%DB31.DBD568
Exhaust Driving Force Offset for switching
BAR/PSI
Real
30
31
32
33 OutputPage2
Vac_Cycle_Delay_Time_SP
%DB31.DBW572
Vaccum Cycle Delay Time SP
%
Int-16
34
35 OutputPage2
Vac_Cycle_Over_Time_SP
%DB31.DBW574
Vaccum Cycle Over Time SP
%
Int-16
36
37 OutputPage2
Exhs_Cycl_PV_Step_Size
%DB31.DBD576
Exhaust Cycle - PV Step Size
%
Real
38
39
40
41 OutputPage2
P2_Pressure_Alarm_Hi_Hi_SP
%DB31.DBD580
P2 - Alarm SP - High High
BAR/PSI
Real
42
43
44
45 OutputPage2
P2_Alarm_Hi_Hi_TMR_SP
%DB31.DBW584
P2 - Alarm Delay SP - High High
10MSEC
Int-16
46
47 OutputPage2
P2_Pressure_Alarm_Lo_Lo_SP
%DB31.DBD586
P2 - Alarm SP - Low Low
BAR/PSI
Real
48
49
50
51 OutputPage2
P2_Alarm_Lo_Lo_TMR_SP
%DB31.DBW590
P2 - Alarm Delay SP - Low Low
10MSEC
Int-16
52
53 OutputPage2
PFLOWMAXSP
%DB31.DBD592
Max Pressure Flow Setpoint
LPM
Real
54
55
56
57 OutputPage2
PFLOWMINSP
%DB31.DBD596
Min Pressure Flow Setpoint
LPM
Real
58
59
60
61 OutputPage2
LastSentInputPage
%DB31.DBW600
Last Sending Data Page Number
Int-16
62
63
%DB31.DBX602
Output Page 3
XCellTM ATF System with C410:V4B Controller User Guide
92
Profibus Address
Tagname plc in DB31
PLC Address
Definition
Units
Data type
Byte #
Bit #
Structure
Tagname in structure
0 OutputPageX
ActiveDataPage
%DB31.DBW310
Active Data Page
Int-16
1
2 0 OutputPageX
ATF_HeartBeat
%DB31.DBX312.0
ATF Heartbeat
Byte 1
OutputPageX
Rem_Profibus
%DB31.DBX312.1
ATF Remote Mode (Profibus)
2 OutputPageX
ATF_Trouble
%DB31.DBX312.2
ATF Common Trouble Alarm
3 OutputPageX
ATF_Running
%DB31.DBX312.3
ATF Run Status 4
OutputPageX
Pump_Alarm_0
%DB31.DBX312.4
Pump Alarm 5
OutputPageX
Pump_Alarm_1
%DB31.DBX312.5
Power Loss While Pump Running Alarm
6 OutputPageX
Pump_Alarm_2
%DB31.DBX312.6
P2 High High Pressure Alarm
0
3
OutputPage3
EFLOWMAXSP
%DB31.DBD604
Max Exhaust Flow Setpoint
LPM
Real 4 5 6 7
OutputPage3
EFLOWMINSP
%DB31.DBD608
Min Exhaust Flow Setpoint
LPM
Real 8 9
10
11 OutputPage3
PTIMEMAXSP
%DB31.DBD612
Max Pressure Flow Setpoint
SEC
Real
12
13
14
15 OutputPage3
PTIMEMINSP
%DB31.DBD616
Min Pressure Flow Setpoint
SEC
Real
16
17
18
19 OutputPage3
ETIMEMAXSP
%DB31.DBD620
Max Exhaust Flow Setpoint
SEC
Real
20
21
22
23 OutputPage3
ETIMEMINSP
%DB31.DBD624
Min Exhaust Flow Setpoint
SEC
Real
24
25
26
27 OutputPage3
PV1MAX
%DB31.DBD628
Flow Proportional Valve Max Value
%
Real
28
29
30
31 OutputPage3
PV1MIN
%DB31.DBD632
Flow Proportional Valve Min Value
%
Real
32
33
34
35 OutputPage3
PV2MAX
%DB31.DBD636
Exhaust Proportional Valve Max Value
%
Real
36
37
38
39 OutputPage3
PV2MIN
%DB31.DBD640
Exhaust Proportional Valve Min Value
%
Real
40
41
42
43 OutputPage3
PRV1MAX
%DB31.DBD644
Pressure Regulator Maximum Value
BAR/PSI
Real
44
45
46
47 OutputPage3
PRV1MIN
%DB31.DBD648
Pressure Regulator Minimum Value
BAR/PSI
Real
48
49
50
51 OutputPage3
PRV2MAX
%DB31.DBD652
Exhaust Regulator Maximum Value
BAR/PSI
Real
52
53
54
55 OutputPage3
PRV2MIN
%DB31.DBD656
Exhaust Regulator Minimum Value
BAR/PSI
Real
56
57
58
59
%DB31.DBD660
60
61
62
63
%DB31.DBX664
Output Page 4
XCellTM ATF System with C410:V4B Controller User Guide
93
Profibus Address
Tagname plc in DB31
PLC Address
Definition
Units
Data type
Byte #
Bit #
Structure
Tagname in structure
0 OutputPageX
ActiveDataPage
%DB31.DBW310
Active Data Page
Int-16
1
2 0
OutputPageX
ATF_HeartBeat
%DB31.DBX312.0
ATF Heartbeat
Byte 1
OutputPageX
Rem_Profibus
%DB31.DBX312.1
ATF Remote Mode (Profibus)
2 OutputPageX
ATF_Trouble
%DB31.DBX312.2
ATF Common Trouble Alarm
3 OutputPageX
ATF_Running
%DB31.DBX312.3
ATF Run Status
4 OutputPageX
Pump_Alarm_0
%DB31.DBX312.4
Pump Alarm 5
OutputPageX
Pump_Alarm_1
%DB31.DBX312.5
Power Loss While Pump Running Alarm
6 OutputPageX
Pump_Alarm_2
%DB31.DBX312.6
P2 High High Pressure Alarm
7
3 0
OutputPage4
P2_Cal_Enable
%DB31.DBX666.0
P2 Cal Select Button
Byte 1
OutputPage4
PRV1_Cal_Enable
%DB31.DBX666.1
PRV1 Cal Select Button
2 OutputPage4
PRV2_Cal_Enable
%DB31.DBX666.2
PRV2 Cal Select Button
3 OutputPage4
P3_Cal_Enable
%DB31.DBX666.3
P3 Cal Select Button
4 OutputPage4
P4_Cal_Enable
%DB31.DBX666.4
P4 Cal Select Button
5 OutputPage4
P5_Cal_Enable
%DB31.DBX666.5
P5 Cal Select Button
6 OutputPage4
W1_Cal_Enable
%DB31.DBX666.6
W1 Cal Select Button
7
%DB31.DBX666.7
4 5
OutputPage4
P2_P1_EU
%DB31.DBD668
P2 First Point Cal Engineering Units
PSI/Bar
Real 6 7 8 9
OutputPage4
P2_P2_EU
%DB31.DBD672
P2 Second Point Cal Engineering Units
PSI/Bar
Real
10
11
12
13 OutputPage4
PRV1_P1_EU
%DB31.DBD676
PRV1 First Point Cal Engineering Units
PSI/Bar
Real
14
15
16
17 OutputPage4
PRV1_P2_EU
%DB31.DBD680
PRV1 Second Point Cal Engineering Units
PSI/Bar
Real
18
19
20
21 OutputPage4
PRV2_P1_EU
%DB31.DBD684
PRV2 First Point Cal Engineering Units
PSI/Bar
Real
22
23
24
25 OutputPage4
PRV2_P2_EU
%DB31.DBD688
PRV2 Second Point Cal Engineering Units
PSI/Bar
Real
26
27
28
29 OutputPage4
P3_P1_EU
%DB31.DBD692
P3 First Point Cal Engineering Units
PSI/Bar
Real
30
31
32
33 OutputPage4
P3_P2_EU
%DB31.DBD696
P3 Second Point Cal Engineering Units
PSI/Bar
Real
34
35
36
XCellTM ATF System with C410:V4B Controller User Guide
94
Output Page 4 (continued)
Profibus Address
Tagname plc in DB31
PLC Address
Definition
Units
Data type
Byte #
Bit #
Structure
Tagname in structure
37 OutputPage4
P4_P1_EU
%DB31.DBD700
P4 First Point Cal Engineering Units
PSI/Bar
Real
38
39
40
41 OutputPage4
P4_P2_EU
%DB31.DBD704
P4 Second Point Cal Engineering Units
PSI/Bar
Real
42
43
44
45 OutputPage4
P5_P1_EU
%DB31.DBD708
P5 First Point Cal Engineering Units
PSI/Bar
Real
46
47
48
49 OutputPage4
P5_P2_EU
%DB31.DBD712
P5 Second Point Cal Engineering Units
PSI/Bar
Real
50
51
52
53 OutputPage4
W1_P1_EU
%DB31.DBD716
W1 First Point Cal Engineering Units
PSI/Bar
Real
54
55
56
57 OutputPage4
W1_P2_EU
%DB31.DBD720
W1 Second Point Cal Engineering Units
KG
Real
58
59
60
61 0 OutputPage4
P2_P1_Capture
%DB31.DBX724.0
1 P2_P2_Capture
%DB31.DBX724.1
2 P2_Accept
%DB31.DBX724.2
3 PRV1_P1_Capture
%DB31.DBX724.3
4 PRV1_P2_Capture
%DB31.DBX724.4
5 PRV1_Accept
%DB31.DBX724.5
6 PRV2_P1_Capture
%DB31.DBX724.6
7 PRV2_P2_Capture
%DB31.DBX724.7
62 0 OutputPage4
PRV2_Accept
%DB31.DBX725.0
1 P3_P1_Capture
%DB31.DBX725.1
2 P3_P2_Capture
%DB31.DBX725.2
3 P3_Accept
%DB31.DBX725.3
4 P4_P1_Capture
%DB31.DBX725.4
5 P4_P2_Capture
%DB31.DBX725.5
6 P4_Accept
%DB31.DBX725.6
7 P5_P1_Capture
%DB31.DBX725.7
63 0 OutputPage4
P5_P2_Capture
%DB31.DBX726.0
1 P5_Accept
%DB31.DBX726.1
2 W1_P1_Capture
%DB31.DBX726.2
3 W1_P2_Capture
%DB31.DBX726.3
4 W1_Accept
%DB31.DBX726.4
5 Solenoid_Forced
%DB31.DBX726.5
6
%DB31.DBX726.6
7
%DB31.DBX726.7
XCellTM ATF System with C410:V4B Controller User Guide
95
Output Page 5
Profibus Address
Tagname plc in DB31
PLC Address
Definition
Units
Data type
Byte #
Bit #
Structure
Tagname in structure
0 OutputPageX
ActiveDataPage
%DB31.DBW310
Active Data Page
Int-16 1 2
OutputPageX
ATF_HeartBeat
%DB31.DBX312.0
ATF Heartbeat
Byte 0
OutputPageX
Rem_Profibus
%DB31.DBX312.1
ATF Remote Mode (Profibus)
0 OutputPageX
ATF_Trouble
%DB31.DBX312.2
ATF Common Trouble Alarm
0 OutputPageX
ATF_Running
%DB31.DBX312.3
ATF Run Status 0
OutputPageX
Pump_Alarm_0
%DB31.DBX312.4
Pump Alarm 0
OutputPageX
Pump_Alarm_1
%DB31.DBX312.5
Power Loss While Pump Running Alarm
0 OutputPageX
Pump_Alarm_2
%DB31.DBX312.6
P2 High High Pressure Alarm
0 OutputPageX
Rem_OPC
%DB31.DBX312.7
ATF Remote Mode (OPC)
3 OutputPage5
FCCT
%DB31.DBD728
Flow Calculated Cycle Time
Real 4 5 6 7
OutputPage5
FACT
%DB31.DBD732
Flow Actual Cycle Time
Real 8 9
10
11 OutputPage5
ECCT
%DB31.DBD736
Exhaust Calculated Cycle Time
Real
12
13
14
15 OutputPage5
EACT
%DB31.DBD740
Exhaust Actual Cycle Time
Real
16
17
18
19 OutputPage5
TRENDTIME
%DB31.DBD744
Trend Time Base
Real
20
21
22
23 OutputPage5
S2TMREAL
%DB31.DBD748
STATE 2 Timer
Real
24
25
26
27 OutputPage5
S5TMREAL
%DB31.DBD752
STATE 5 Timer
Real
28
29
30
31 OutputPage5
S2DUR
%DB31.DBD756
STATE 2 Duration
Int-32
32
33
34
35 OutputPage5
S5DUR
%DB31.DBD760
STATE 5 Duration
Int-32
36
37
38
39 OutputPage5
CYCLENO
%DB31.DBD764
Batch Cycle Count
Int-32
40
41
42
43 OutputPage5
TOTAL_CYCLENO
%DB31.DBD768
Total Cycle Count
Int-32
44
(Can only be reset by service)
45
46
47 OutputPage5
APC_PFlowPrimary
%DB31.DBD772
Algorithm Perfomance Counter - P-Flow - Primary
Int-32
48
49
50
51 OutputPage5
APC_VFlowPrimary
%DB31.DBD776
Algorithm Perfomance Counter - V-Flow - Primary
Int-32
52
53
54
55
56
57
58
59
60
61
62
63
XCellTM ATF System with C410:V4B Controller User Guide
96
Appendix 6: Delta V Example configuration
This example shows a Siemens CM 1242-5 card (slave module) being added to a Delta V
controller configuration.
1.1 Install the GSD File in Delta V Explorer
Open under the DeltaV_System, Library > Device Definitions > Profibus Devices.
Select “Add Device Definition…”
Loading...