REPLIGEN XCell ATF Series User Manual
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REPLIGEN XCell ATF Series User Manual

With c410:v4b controller
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XCell
ATF System
With C410:V4B Controller
USER GUIDE
XCell ™ ATF4 | XCell ™ ATF6 | XCell ™ ATF10

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Summary of Contents for REPLIGEN XCell ATF Series

  • Page 1 XCell ATF System With C410:V4B Controller USER GUIDE XCell ™ ATF4 | XCell ™ ATF6 | XCell ™ ATF10...
  • Page 2 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.

  • Page 3: Table Of Contents

    XCell 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 XCell ATF System Pump Cycle ..................3 1.2 XCell™ ATF System Control Scope and Objectives ............5 2.0 Utility Requirements ......................
  • Page 4 XCell 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”...

  • Page 5: Description Of The Xcell™ Atf (Alternating Tangential Flow) System And Process

    XCell ATF System with C410:V4B Controller User Guide 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.
  • Page 6 XCell ATF System with C410:V4B Controller User Guide 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.

  • Page 7: Xcell Tm Atf System Pump Cycle

    XCell ATF System with C410:V4B Controller User Guide XCell 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.
  • Page 8 XCell ATF System with C410:V4B Controller User Guide 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.

  • Page 9: Xcell™ Atf System Control Scope And Objectives

    SECONDARY Typically: 35 psi / 2.4bar, Regulated oil free, dry, filtered air PRESSURE Vacuum supplied by a Repligen or customer supplied local pump capable of maintaining ~-12.5 psig with nominal flow as follows: VACUUM SERVICE Minimum -12.5 psig XCell™...

  • Page 10: Dimensions And Weight

    XCell ATF System with C410:V4B Controller User Guide 3.0 Dimensions and Weight COMPONENT DIMENSIONS DESCRIPTION C410v4B Controller inches PNEUMATIC BOX 10.5 Includes all plugs and connectors. ELECTRIC BOX (Controls) Includes all plugs and connectors. POWER BOX 10.5 (Power Separation) Includes all plugs and connectors. Filtration Assembly Fully assembled system XCell™...

  • Page 11: Xcell™ Atf Pump Housing Assemblies

    XCell ATF System with C410:V4B Controller User Guide 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.
  • Page 12 XCell ATF System with C410:V4B Controller User Guide Table 4a. XCell™ ATF 10 Pump Housing Parts List ITEM DESCRIPTION Material QTY. ASME Clamp, Assembly, XCell™ 316 SS ATF10 Pump Hemisphere Air Side, SA479 316L SS XCell™ ATF10 Lifting Handle, Assembly, XCell™ 316 SS ATF10 Pump Hemisphere Liquid Side,...
  • Page 13 XCell ATF System with C410:V4B Controller User Guide Figure 4b. Exploded View of XCell™ ATF 10 Single-use Device with 0.2u PES Hollow Fiber Filter...
  • Page 14 XCell ATF System with C410:V4B Controller User Guide Table 4b. XCell™ ATF 10 Single-use Device Components Item DESCRIPTION MATERIAL Housing Tube Assembly, suATF10 Polycarbonate (Lexan) HPS6 Spectrum F10 2 Micron PES Hollow Fiber Cartridge 0.295” C/S x 6.835” ID x 7.425” OD O-Ring, 50A Silicone Hardness, Clear Reducer, Spectrum, su ATF10...
  • Page 15 XCell ATF System with C410:V4B Controller User Guide Figure 4c. Exploded View of XCell™ ATF 6 System Filtration Assembly (P/N ATF6:PH‐GMP)

  • Page 16: See Appendix 7 For List Of Spares And Accessories

    XCell ATF System with C410:V4B Controller User Guide Table 4c. XCell™ ATF 6 Pump Housing Parts List Item DESCRIPTION MATERIAL Pump Hemisphere, Base Plate, Assembly, ATF6 AISI Type 316L Stainless Steel Socket Head Cap Screw, ¼-20 x 3/8 LG 18-8 SS Pump Hemisphere, Air Side, ATF 6 SA479 316L SS Socket Set Screw, Cup Point, 3/8-16 UNC x ½...
  • Page 17 XCell ATF System with C410:V4B Controller User Guide Figure 4d. Exploded View of XCell™ ATF 6 Single-use Device with 0.2u PES Hollow Fiber Filter...
  • Page 18 XCell ATF System with C410:V4B Controller User Guide Table 4d. XCell™ ATF 6 Single-use Device Components Item Item Description Material Pump Hemisphere: Air Side: XCell suATF6 Polycarbonate (Lexan) HPS6 Diaphragm: Pump: ATF6 50A P.C. Silicone: BlueStar LSR 4350 Pump Hemisphere: Liquid Side: XCell suATF6 Polycarbonate (Lexan) HPS6 Housing Tube: XCell suATF6...
  • Page 19 XCell ATF System with C410:V4B Controller User Guide Figure 4e. Exploded View of XCell™ ATF 4 System Filtration Assembly (P/N XCell™ ATF4:PH‐GMP)
  • Page 20 XCell ATF System with C410:V4B Controller User Guide Table 4e. XCell™ ATF 4 Pump Housing Parts List Item DESCRIPTION MATERIAL Pump Hemisphere, Air Side, ATF4 SA 479 31 6L SS MS/SAE Male Straight Threaded Connector AISI Type 31 6L Stainless Steel 7/16 - 20 x 3/8”...

  • Page 21: Xcell Tm C410V4B Controller Layout

    XCell ATF System with C410:V4B Controller User Guide 5.0 XCell C410v4B Controller Layout 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™...

  • Page 22: Filtration Assembly (Stainless Steel)

    XCell ATF System with C410:V4B Controller User Guide 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.
  • Page 23 XCell ATF System with C410:V4B Controller User Guide Electrical Box Components a. NA (not available for C410v4B controller) 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 HMI/OIT Display g.

  • Page 24: Power Box (Power Separation) Components

    XCell ATF System with C410:V4B Controller User Guide Power Box (Power Separation) Components Interconnected Cable Plug (power) 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 Primary Pneumatic Services Air inlet (q) - Located on the P-Box and provides an inlet to house compressed air source.

  • Page 25: Primary Electric Services

    XCell ATF System with C410:V4B Controller User Guide 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.

  • Page 26: C410V4B Controller Process And Control

    XCell ATF System with C410:V4B Controller User Guide 6.0 C410v4B Controller Process and Control 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.
  • Page 27 XCell ATF System with C410:V4B Controller User Guide 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™...

  • Page 28: Control Functional Algorithms

    XCell ATF System with C410:V4B Controller User Guide Figure 6. Instrument Flow Control Schematic of C410v4B Controller SOL1 MANUAL AUTOMATIC PRESSURE PRESSURE REGULATOR PRESSURE REGULATOR SENSOR PRV1 PROPORTIONAL VALVE TO PUMP INCOMING AIR PROPORTIONAL VALVE EXHAUST (VACUUM) AUTOMATIC VACUUM REGULATOR PRV2 XCell™...

  • Page 29: Interface And Screens

    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.
  • Page 30 XCell ATF System with C410:V4B Controller User Guide Description of Screens and Buttons 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.
  • Page 31 XCell ATF System with C410:V4B Controller User Guide MAIN 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.
  • Page 32 XCell ATF System with C410:V4B Controller User Guide 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 Field entries by Administrator (or, if authorized, by Engineer) through the Screen Main screen: P-FLOW SP, E- FLOW SP, PV1, PRV1, PV2, PRV2 P-FLOW SP...
  • Page 33 XCell ATF System with C410:V4B Controller User Guide 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...
  • Page 34 XCell ATF System with C410:V4B Controller User Guide SET UP 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 •...
  • Page 35 XCell ATF System with C410:V4B Controller User Guide 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 The Prefix assigned to the bioreactor connected to the XCell™ ATF Prefix system.
  • Page 36 XCell ATF System with C410:V4B Controller User Guide ADVANCED SET UP From the Advanced Set Up Engineer/Administrator can set the following Diaphragm Pump Parameters:...
  • Page 37 XCell ATF System with C410:V4B Controller User Guide 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.)
  • Page 38 XCell ATF System with C410:V4B Controller User Guide START-UP GUIDE 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...
  • Page 39 XCell ATF System with C410:V4B Controller User Guide CALIBRATION 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).
  • Page 40 XCell ATF System with C410:V4B Controller User Guide 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...
  • Page 41 XCell ATF System with C410:V4B Controller User Guide TRENDING The Trending screen displays an Overview screen from where the following trends are selected. PROCESS TREND This screen monitors, in real time, the Flow and Exhaust Set Points and Process Values in Liters per Minute( LPM).
  • Page 42 XCell ATF System with C410:V4B Controller User Guide 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 Enter maximum value for the chart Y Axis Enter minimum value for the chart Y Axis Button Description...
  • Page 43 XCell ATF System with C410:V4B Controller User Guide 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 Enter maximum value for the chart Y Axis Enter minimum value for the chart Y Axis Button Description...
  • Page 44 XCell ATF System with C410:V4B Controller User Guide 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.
  • Page 45 XCell ATF System with C410:V4B Controller User Guide ALARMS 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.
  • Page 46 XCell ATF System with C410:V4B Controller User Guide Two (2) Pump Controller Status Relays are provided which energize per the following states: XCell™ ATF System State # RELAY #1 RELAY #2 States POWER OFF / ALARM POWER ON / STANDBY POWER ON / RUNNING POWER ON /...
  • Page 47 XCell ATF System with C410:V4B Controller User Guide ADMIN. 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: USERS The screen allows creation/amending of User ID’s and passwords. There are three (3) levels of security: 1.
  • Page 48 XCell ATF System with C410:V4B Controller User Guide 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.
  • Page 49 XCell ATF System with C410:V4B Controller User Guide BASIC 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 Total number of pump cycles of all batches since reset Cycles...
  • Page 50 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.
  • Page 51 XCell ATF System with C410:V4B Controller User Guide 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 Only visible in local mode, when XCell™ ATF pump is stopped and no buttons calibration activities are enabled.
  • Page 52 XCell ATF System with C410:V4B Controller User Guide BATCH INFO. Display batch information as in the following screens OVERVIEW 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.
  • Page 53 XCell ATF System with C410:V4B Controller User Guide ALGORITHM 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.

  • Page 54: Startup

    XCell ATF System with C410:V4B Controller User Guide LOGOFF. On User logoff, the controller continues to operate normally. A user must log back on to make changes to setting. Startup Assembly of the XCell™ ATF System is described in the following sections. This section provides a startup guide for an XCell™...
  • Page 55 XCell ATF System with C410:V4B Controller User Guide 6.4.4 Go to the ADVANCED SET UP screen and enter the following field values Field VALUES XCell™ ATF XCell™ ATF XCell™ XCell™ ATF XCell™ ATF User Set Point Range ATF 6 10lgcy Max P-FLOW (LPM) Min P-FLOW (LPM) Max E-FLOW (LPM)

  • Page 56: Examples

    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.
  • Page 57 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.

  • Page 58: Xcell™ Atf Hollow Fiber Module And Diaphragm Replacement

    XCell ATF System with C410:V4B Controller User Guide 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.

  • Page 59: Hfm Insertion

    XCell ATF System with C410:V4B Controller User Guide 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.

  • Page 60: Screen Module Replacement

    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. Screen Module replacement If the SM is being used, contact Repligen at Customer Service at Sales@Repligen.com replacement instructions. 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™...

  • Page 61: Assembly

    XCell ATF System with C410:V4B Controller User Guide 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.

  • Page 62: Sterilization

    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™...

  • Page 63: Autoclave Cycle

    XCell ATF System with C410:V4B Controller User Guide 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.

  • Page 64: Sterilization Of Filtrate / Harvest Line

    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...

  • Page 65: Connection To Bioreactor (Atf-To-Bioreactor)

    XCell ATF System with C410:V4B Controller User Guide 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.

  • Page 66: Maintenance

    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.

  • Page 67: Appendix 1: Cycle Time Vs. Flow Rate

    XCell ATF System with C410:V4B Controller User Guide Appendix 1: Cycle time vs. Flow rate XCell™ ATF 4 XCell™ ATF XCell™ ATF XCell™ ATF System XCell™ ATF 6 &4MC PUMP VOLUME (L) Cycle time (sec) FLOW RATE (L/MIN) 18.8 76.5 90.0 12.5 51.0...

  • Page 68: Appendix 2: Access Levels To The C410V4B Controller

    XCell ATF System with C410:V4B Controller User Guide 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.
  • Page 69 XCell ATF System with C410:V4B Controller User Guide User Level Screen Controller Function Parameter Permissions Name View Only Elapsed Time View Only Batch Data Batch Info - Cycle Count View Only Overview User ID View Only Name View Only Batch Setup Reset View Only General Access...
  • Page 70 XCell ATF System with C410:V4B Controller User Guide User Level Screen Controller Function Parameter Permissions General Access General Access Upon Login Start/Stop General Allowed Allowed Remote/Local Toggle Allowed LMP SP Allowed to Change LPM PV View only PFlow Status Sec Calculated View Only Sec Actual View Only...
  • Page 71 XCell ATF System with C410:V4B Controller User Guide User Level Screen Controller Function Parameter Permissions Name View Only Elapsed Time View Only Batch Data Batch Info - Cycle Count View Only Overview User ID View Only Name Allowed to Change Batch Setup Reset Allowed...
  • Page 72 XCell ATF System with C410:V4B Controller User Guide User Level Screen Controller Function Parameter Permissions General Access General Access Upon Login Start/Stop General Allowed Allowed Remote/Local Toggle Allowed LMP SP Allowed to Change LPM PV View only PFlow Status Sec Calculated View Only Sec Actual View Only...
  • Page 73 XCell ATF System with C410:V4B Controller User Guide User Level Screen Controller Function Parameter Permissions User ID View Only Name Allowed to Change Batch Setup Reset Allowed General Access View Allowed Batch Info – Algorithm Algorithm Reset Allowed Performance Pump Model Allowed to Change Control Mode Allowed to Change...
  • Page 74 XCell ATF System with C410:V4B Controller User Guide User Level Screen Controller Function Parameter Permissions Sol. Force Off/On Allowed Clean Screen Access Allowed Date/Time Input Value Allowed Allowed (when in Pressure Units Toggle PSI/Bar local mode) Logon Splash Toggle Allowed Profibus 1 Access Allowed...

  • Page 75: Appendix 3: Controller Lists: Alarm, Warning, Inputs & Outputs

    XCell ATF System with C410:V4B Controller User Guide Appendix 3: Controller Lists: Alarm, Warning, Inputs & Outputs Alarms/Warning List Alarm Tag Name Description Enable Condition Delay Action Number of XCell™ ATF Pump is minute(s). Warning condition Running and Alarm, Determined by has not been reset Alarm Delay System Stop,...
  • Page 76 XCell ATF System with C410:V4B Controller User Guide Input/ Output List Engineering Valve Fail Real Time Tag Name Description PLC Tag Address Position Trend Range Decimal Places Units System Stop %I0.0 System Stop %I0.1 Spare Spare Spare Spare Spare Spare Spare Spare Spare...

  • Page 77: Appendix 4: Profinet Communication

    XCell ATF System with C410:V4B Controller User Guide 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).
  • Page 78 XCell ATF System with C410:V4B Controller User Guide 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.

  • Page 79: Appendix 5: Profibus Communication

    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.
  • Page 80 XCell ATF System with C410:V4B Controller User Guide 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).
  • Page 81 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.
  • Page 82 XCell ATF System with C410:V4B Controller User Guide 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.
  • Page 83 XCell ATF System with C410:V4B Controller User Guide 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.
  • Page 84 XCell ATF System with C410:V4B Controller User Guide 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 Tagname plc in DB31 Data Address type PLC Address Definition...
  • Page 85 XCell ATF System with C410:V4B Controller User Guide Input Page 1 Profibus Address Tagname plc in DB31 Data type PLC Address Definition Units Byte # Bit # Structure Tagname in structure InputPageX PB_ATF_START_STOP %DB31.DBX128.0 AFT 1=Start/0=Stop Byte InputPageX PB_ATF_Ack_Alarms %DB31.DBX128.1 ATF Acknowledge Alarms InputPageX PB_Reset_Counters...
  • Page 86 XCell ATF System with C410:V4B Controller User Guide Input Page 2 Profibus Address Tagname plc in DB31 PLC Address Definition Units Data type Byte # Bit # Structure Tagname in structure InputPageX PB_ATF_START_STOP %DB31.DBX128.0 AFT 1=Start/0=Stop Byte InputPageX PB_ATF_Ack_Alarms %DB31.DBX128.1 ATF Acknowledge Alarms InputPageX PB_Reset_Counters...
  • Page 87 XCell ATF System with C410:V4B Controller User Guide Input Page 3 Profibus Address Tagname plc in DB31 PLC Address Definition Units Data type Byte # Bit # Structure Tagname in structure InputPageX P2_Cal_Enable %DB31.DBX376.0 P2 Cal Select Button Byte InputPageX PRV1_Cal_Enable %DB31.DBX376.1 PRV1 Cal Select Button...
  • Page 88 XCell ATF System with C410:V4B Controller User Guide Input Page 3 (Continued) Profibus Address Tagname plc in DB31 Data type PLC Address Definition Units Byte # Bit # Structure Tagname in structure Force_Solenoid %DB31.DBD431.4 55..63 Unused...
  • Page 89 XCell ATF System with C410:V4B Controller User Guide Input Page 4 Profibus Address Tagname plc in DB31 PLC Address Definition Units Data type Byte # Bit # Structure Tagname in structure InputPageX P2_Cal_Enable %DB31.DBX432.0 P2 Cal Select Button Byte InputPageX PRV1_Cal_Enable %DB31.DBX432.1 PRV1 Cal Select Button...
  • Page 90 XCell ATF System with C410:V4B Controller User Guide Input Page 4 (Continued) Profibus Address Tagname plc in DB31 PLC Address Definition Units Data type Byte # Bit # Structure Tagname in structure 55..63 Unused...
  • Page 91 XCell ATF System with C410:V4B Controller User Guide 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.
  • Page 92 XCell ATF System with C410:V4B Controller User Guide Output Page 0 (continued) Profibus Address Tagname plc in DB31 PLC Address Definition Units Data type Byte # Bit # Structure Tagname in structure OutputPage0 Warning_0 %DB31.DBX366.0 PV1>=PV1Max Byte OutputPage0 Warning_1 %DB31.DBX366.1 PV1<=PV1Min OutputPage0 Warning_2 %DB31.DBX366.2 PV2>=PV2Max OutputPage0 Warning_3...
  • Page 93 XCell ATF System with C410:V4B Controller User Guide Output Page 1 Profibus Address Tagname plc in DB31 PLC Address Definition Units Data type Byte # Bit # Structure Tagname in structure OutputPageX ActiveDataPage %DB31.DBW310 Active Data Page Int-16 OutputPageX ATF_HeartBeat %DB31.DBX312.0 ATF Heartbeat Byte OutputPageX Rem_Profibus...
  • Page 94 XCell ATF System with C410:V4B Controller User Guide Output Page 1 (Continued) Profibus Address Tagname plc in DB31 PLC Address Definition Units Data type Byte # Bit # Structure Tagname in structure OutputPage1 AIW08_Cal_Accept_Vis %DB31.DBD509.0 AIW12_Cal_Enable %DB31.DBD509.1 AIW12_Cal_Accept_Vis %DB31.DBD509.2 AIW14_Cal_Enable %DB31.DBD509.3 AIW14_Cal_Accept_Vis %DB31.DBD509.4...
  • Page 95 XCell ATF System with C410:V4B Controller User Guide Output Page 2 Profibus Address Tagname plc in DB31 PLC Address Definition Units Data type Byte # Bit # Structure Tagname in structure OutputPageX ActiveDataPage %DB31.DBW310 Active Data Page Int-16 OutputPageX ATF_HeartBeat %DB31.DBX312.0 ATF Heartbeat Byte...
  • Page 96 XCell ATF System with C410:V4B Controller User Guide Profibus Address Tagname plc in DB31 PLC Address Definition Units Data type Byte # Bit # Structure Tagname in structure OutputPageX ActiveDataPage %DB31.DBW310 Active Data Page Int-16 OutputPageX ATF_HeartBeat %DB31.DBX312.0 ATF Heartbeat Byte OutputPageX Rem_Profibus...
  • Page 97 XCell ATF System with C410:V4B Controller User Guide Profibus Address Tagname plc in DB31 PLC Address Definition Units Data type Byte # Bit # Structure Tagname in structure OutputPageX ActiveDataPage %DB31.DBW310 Active Data Page Int-16 OutputPageX ATF_HeartBeat %DB31.DBX312.0 ATF Heartbeat Byte OutputPageX Rem_Profibus %DB31.DBX312.1 ATF Remote Mode (Profibus)
  • Page 98 XCell ATF System with C410:V4B Controller User Guide Output Page 4 (continued) Profibus Address Tagname plc in DB31 PLC Address Definition Units Data type Byte # Bit # Structure Tagname in structure OutputPage4 P4_P1_EU %DB31.DBD700 P4 First Point Cal Engineering Units PSI/Bar Real OutputPage4 P4_P2_EU...
  • Page 99 XCell ATF System with C410:V4B Controller User Guide Output Page 5 Profibus Address Tagname plc in DB31 PLC Address Definition Units Data type Byte # Bit # Structure Tagname in structure OutputPageX ActiveDataPage %DB31.DBW310 Active Data Page Int-16 OutputPageX ATF_HeartBeat %DB31.DBX312.0 ATF Heartbeat Byte...

  • Page 100: Appendix 6: Delta V Example Configuration

    XCell ATF System with C410:V4B Controller User Guide 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 >...
  • Page 101 XCell ATF System with C410:V4B Controller User Guide 1.2 Add new Profibus Device Open under the DeltaV_System, System Configuration > Physical Network > Control Network > VIM > I/O > C01 > P01. Select “New Profibus Device”...
  • Page 102 XCell ATF System with C410:V4B Controller User Guide 1.3 Select Profibus Device Type Select the correct Profibus Type (Generated by the GSD file). In this case a Siemens CM 1242-5 card is shown. 1.4 Address Setting Verify that the “Enabled” checkbox is checked and the “Address” field matches the Address set on the Admin page on the HMI.
  • Page 103 XCell ATF System with C410:V4B Controller User Guide 1.6 Verify “Enabled” If this is the first device on the Profibus Card, reopen the port and verify that the “enabled” checkbox is checked. 1.7 Create Slot Create a “New Profibus Slot” for the new Profibus Device.
  • Page 104 XCell ATF System with C410:V4B Controller User Guide 1.8 Set Slot Size In Delta V the Slot size can be 1, 2, 4, 8, 16, 20 or 64 bytes or words. The largest is 64 words (or 128 bytes). For the XCell™ ATF equipment: •...
  • Page 105 XCell ATF System with C410:V4B Controller User Guide 1.10 Create Signals In the Delta V Slot, create a “New Profibus Signal” 1.11 Create a Real datatype tag For a REAL tag to be read from the XCell™ ATF controller, select the Data Type: Floating Point. “Standard network Byte order”...
  • Page 106 XCell ATF System with C410:V4B Controller User Guide This Appendix is intended to provide some limited guidance to an experience Delta V controls professional to avoid standard configuration inquiries which has been experienced by previous integrators.

  • Page 107: Appendix 7: Opc Communication

    XCell ATF System with C410:V4B Controller User Guide Appendix 7: OPC Communication XCell™ ATF Operations- Remote Monitoring and Data Acquisition The following diagram shows the network architecture for controlling the XCell™ ATF Equipment from an OPC Server and OPC Client Software over Profinet®: The OPC Client Software is any OPC capable program that will connect through the OPC Server to the XCell™...
  • Page 108 XCell ATF System with C410:V4B Controller User Guide The XCell™ ATF C410v4 controller is capable of remote operation using the standard Ethernet (Profinet) port onboard, enabling communication to an OPC server (master customer). To activate this control mode, the selector switch on the Administrator screen must be toggled to OPC. See section F.2 Basic Administration Screen (Remote Mode Connection) selector switch.
  • Page 109 The master sends enable, capture and accept commands as well as high and low scaling parameters to perform calibration activities, or calibration can be performed via the HMI. 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...
  • Page 110 XCell ATF System with C410:V4B Controller User Guide 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.
  • Page 111 XCell ATF System with C410:V4B Controller User Guide d. Reset 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. Set PV1_SP = 100 Confirmed by examining DL_PV1 b.
  • Page 112 XCell ATF System with C410:V4B Controller User Guide OPC Inputs Tagname plc in DB41 Data PLC Address Definition Units type Structure Tagname in structure "DB41". ATF_START %DB41.DBX0.0 Command Word - ATF Start Bool "DB41". ATF_STOP %DB41.DBX0.1 Command Word - ATF Stop Bool "DB41".
  • Page 113 XCell ATF System with C410:V4B Controller User Guide OPC Inputs (continued) Tagname plc in DB41 Data PLC Address Definition Units type Structure Tagname in structure "DB41". P2_Cal_Enable %DB41.DBX152.0 Bool "DB41". PRV1_Cal_Enable %DB41.DBX152.1 Bool "DB41". PRV2_Cal_Enable %DB41.DBX152.2 Bool "DB41". P3_Cal_Enable %DB41.DBX152.3 Bool "DB41".
  • Page 114 XCell ATF System with C410:V4B Controller User Guide OPC Outputs Tagname plc in DB40 Data PLC Address Definition Units type Structure Tagname in structure "DB40". DB40_DataLog.DL_BATCH_NO P#DB40.DBX0.0 Batch Number String "DB40". DB40_DataLog.DL_CYCLENO %DB40.DBD256 Batch Cycle Count DInt "DB40". DB40_DataLog.DL_TOTAL_CYCLENO %DB40.DBD260 Total Cycle Count (resettable by Service) DInt "DB40".
  • Page 115 XCell ATF System with C410:V4B Controller User Guide OPC Outputs (continued) Tagname plc in DB40 Data PLC Address Definition Units type Structure Tagname in structure "DB40". DB40_DataLog.DL_APC_VFlowPrimary %DB40.DBW458 Algorithm Performance Counter 3 "DB40". DB40_DataLog.DL_APC_VFlowOverride %DB40.DBW460 Algorithm Performance Counter 4 "DB40". DB40_DataLog.DL_APC_VFlowOvertime %DB40.DBW462 Algorithm Performance Counter 5...
  • Page 116 XCell ATF System with C410:V4B Controller User Guide OPC Outputs (continued; calibration parameters) Tagname plc in DB40 Data PLC Address Definition Units type Structure Tagname in structure "DB40". P2_Cal_Enabled %DB40.DBX540.0 P2 Cal Select Button Bool "DB40". PRV1_Cal_Enabled %DB40.DBX540.1 PRV1 Cal Select Button Bool "DB40".

  • Page 117: Appendix 8: Audit Trail (If Equipped)

    XCell ATF System with C410:V4B Controller User Guide Appendix 8: Audit Trail (If Equipped) Note: Audit trail functionality is available on systems with HMI software version 4.36 or higher. The C410v4B controller has the ability to be equipped with software that will enable audit trail recording of HMI inputs.
  • Page 118 XCell ATF System with C410:V4B Controller User Guide Description Name P2 Alarm Limit Lo Lo Set Point P2_Pressure_Alarm_Lo_Lo_SP P2 Pressure Alarm Lo Lo - Timer SP P2_Alarm_Lo_Lo_TMR_SP Max Pressure Flow Setpoint LPM PFLOWMAXSP Min Pressure Flow Setpoint LPM PFLOWMINSP Max Exhaust Flow Setpoint LPM EFLOWMAXSP Min Exhaust Flow Setpoint LPM EFLOWMINSP...
  • Page 119 XCell ATF System with C410:V4B Controller User Guide Description Name Calibration - AIW04 - Point 1 - Engineering Value P2_P1_EU Calibration - AIW04 - Point 2 - Engineering Value P2_P2_EU Calibration - AIW06 - Point 1 - Engineering Value PRV1_P1_EU Calibration - AIW06 - Point 2 - Engineering Value PRV1_P2_EU Calibration - AIW08 - Point 1 - Engineering Value...

  • Page 120: Appendix 9: Eu Declaration Of Conformity

    XCell ATF System with C410:V4B Controller User Guide Appendix 9: Example EU Declaration of Conformity The C410v4B Controller for XCell™ ATF 4, XCell™ ATF 6, XCell™ ATF8 and XCell™ ATF 10 system operation has been assessed for compliance with applicable CE Directives. A sample Declaration of Conformity certificate is shown below.
  • Page 121 XCell ATF System with C410:V4B Controller User Guide Sample Nameplate The XCell™ ATF System with C410 Controller, software v4B, has been marked legibly and indelibly with thefollowing information: • Name and address of the manufacturer • Rated voltage, full load amperage, and frequency •...
  • Page 122 User Guide General Information and handling Instructions 1. Repligen XCell™ ATF system is rated for acceptable sound levels (60 dBA) 2. Weight of C410 controller: E-Box 23 kg (50 lbs), P-Box 13 kg (28.6 lbs) 3. Complete system visual inspection for damage or potential risk to the operator, surrounding personal, or equipment on a semi-annual basis 4.

  • Page 123: Appendix 10: Ul Listing

    User Guide Appendix 10: UL Listing All Repligen XCell™ ATF controller power separation boxes are ‘UL Listed’. UL Listing indicates that Underwriter Laboratories has tested representative samples of the product and determined that it meets UL’s requirements. These requirements are based on UL’s published and nationally recognized Standards for Safety.

  • Page 124: Appendix 11: Spares List

    XCell ATF System with C410:V4B Controller User Guide Appendix 11: Spare Parts List XCell™ ATF Electronics Spares Pushbutton, 22 mm Metal Latch with Twist-to-Release LED Illuminated Red, C410:EP-AD-CB-NC 24 VAC/DC, 40 mm Mushroom Operator 1 N.C. Contact Block Selector switch, 22 mm metal 2-posisiton, maintained LED illuminated C410:E-AD-CB-NO-1252 24VAC/DC knob operator 1 n.o.
  • Page 125 XCell ATF System with C410:V4B Controller User Guide XCell™ ATF 6 Pump Housing Spares A6-H1 Filter Housing Assembly, XCell™ ATF6 A6:R1 Reducer, XCell™ ATF6 XCell™ ATF6:PHLA Pump Hemisphere, Liquid Side Assembly, XCell™ ATF6 A6-BASE Pump Hemisphere, Base Plate, Assembly, XCell™ ATF6 SG-05-E Sanitary Gasket, 1/2"...
  • Page 126 Air Inlet Assembly, XCell™ ATF10 XCell™ ATF10:PH-AA-AIR Air Hemisphere, XCell™ ATF10 w/XCell™ ATF10:AIR-ASSY P3-CPM1.5-TC3/4 Kit, PT, 1.5"CPM Fitting, 3/4"TC For additional service support please contact Repligen at (800) 622-2259 or CustomerServiceUS@repligen.com. Repligen, 41 Seyon St., Building 1, Suite 100, Waltham MA, 02453...

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