Malema BCV-980 Manual de usuario

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Corporate Headquarters West Coast Headquarters Asia Pacic Headquarters

1060 S Rogers Circle

Boca Raton, FL 33487

P: (561) 995-0595 F: (561) 995-0622

2329 Zanker Road

San Jose, CA 95131

P: (408) 970-3419 F: (408) 970-3426

35, Marsiling Industrial Estate Road 3,

02-06, Singapore 739257

P: (65) 6482-3533 F: (65) 6484-4231

INSTRUCTION MANUAL

FOR

BCV-980

Bio-Pharmaceucal Proporonal

Pinch Control Valve

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INTRODUCTION:

The BCV-980 is an intelligent, Proporonal Control Valve intended for BioPharmacucal applicaons. The BCV is an electrically

operated Pinch Valve with built-in, sophiscated control capabilies. Electrically operated Pinch valves oer several advantages

over other valve construcons. For BioPharama applicaons these advantages include:

• No added materials in contact with the media; only the tube-manifold contacts the media

• No crevasses, cracks, clogging or dead spots

• Unaected by parculates in the stream

• Simple, robust & straight through design

• No Pneumac complicaons or facilies required for operaon

• Self-cleaning

• Tight shuto

• Minimal turbulence & fricon

• Minimal maintenance required. No bearings, seals or packings

• Low Total Cost of Ownership; other than the single use manifold there are no other consumables

Classic pinch valves provide minimal throling control capabilies; most of the control occurs during the rst 1/4 to 1/3 of the

control range [Coecient of Determinaon, i.e.: R2 values around 66%]. Malema ulizes a complex polynomial algorithm

expanding upon the classic performance

of pinch valves. By linearizing valve perfor-

mance [ow rate] Vs. control signal rather

than linearizing valve posion Vs. control

signal. While using Malema’s linearizaon

scheme a slight change in control signal re-

sults in a similar [linear] change in ow rate

[Coecient of Determinaon, i.e.: R2 >95%].

This proprietary linearizaon scheme can be

disabled from Malema’s GUI.

Control Resoluon: The BCV-980 ulizes a ten(10) pitch [i.e.: ten(10) threads per inch] Acme screw and an eight thousand

(8,000) count per revoluon opcal encoder monitoring valve posion. A sixteen(16) bit ADC converts the command setpoint

signal into 65K steps between fully OPEN and fully CLOSED posions. Assuming one hundred LPM is the max ow through a

1” ID tube, individual step resoluon is about 5 ccm or ≈ 0.5% of Full Scale.

Resoluon varies with tube size. Smaller sized tubes may have fewer total steps available. Malema oers a high resoluon ver-

sion for these applicaons.

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Table of Contents

INTRODUCTION 2

OPERATING MODES 4

SAFETY, CAUTIONS 5

DIMENSIONAL DRAWINGS 5

PRODUCT SPECIFICATIONS 6

GETTING STARTED 7

TUBING INSTALLATION 8

REMOTE MANIFOLD INSTALL COMMAND 8

PANEL MOUNTING 9

CALIBRATION, LINEARIZATION 10

PINOUT, WIRING Diagrams 12

CIRCUIT DIAGRAMS 14

CABEL DETAILS 17

FRONT PANEL DISPLAY 16

TYPICAL, STAND-A-LONE TFF APPLICATION 17

CONTROL STRATEGY 18

MALEMA GUI 18

GUI CONTROL WINDOW 20

WARRANTY 21

CERTIFICATE OF COMPLIANCE 23

APENDIX of SELECTED DATA 24

Malema, Malema Sensors, and Malema Engineering Corporaon are service marks of Malema Engineering Corporaon. All other trademarks are property of their respecve owners.

Malema supplies this publicaon for informaonal purposes only. While every eort has been made to ensure accuracy, this publicaon is not intended to make performance claims or

process recommendaons. Malema does not warrant, guarantee, or assume any legal liability for the accuracy, completeness, meliness, reliability, or usefulness of any informaon, product,

or process described herein. We reserve the right to modify or improve the designs or specicaons of our products at any me without noce. For actual product informaon and recom-

mendaons, please contact your local Malema representave.

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INTRODUCTION (CONTINUED)

OPERATING MODES:

The BVC-980 is an intelligent, proporonal, pinch, control valve.

1. The BCV-980 – Supports 1/8” through 1”I.D. tubing

2. The BCV-980 supports virtually any biopharma tube construcon including:

a. Unreinforced tubing

b. Braid Reinforced tubing, or

c. Double Braid Reinforced tubing

The product has two(2) operang modes:

1. REMOTE Mode: In this mode, the device responds to an external 4 to 20 mA signal generated by a remote

operator or control system [i.e.: 4 mA = FULLY CLOSED; 20 mA = FULLY OPEN]. Valve posion is soware adjusted to

approximately linearize ow rate Vs. signal [I.e.: 12 mA ~= 50% FLOW]

2. TFF Mode: Based on an analog Setpoint signal, the device monitors up to three(3), external analog transducer

signals, adjusng valve posion based on the TFF Equaon. On applicaon, other algorithms can be supported.Conrm

that you have the following items:

When panel mounted in a standard 1/4 DIN panel cut-out [88 mm X 88 mm], the BCV-980 provides IP65 (protecon against

water jets) NOTE: Care must be taken in a panel layout as the exible tube running through a BCV-980 may obscure adjacent

panel cut-out locaons. The BCV-980 supports mounng in any orientaon.

The BCV-980 accepts tubing of virtually any size between 0.125” ID through 1.000” ID. Factory pre-conguraon for any size

or tube conguraon is available and recommended. One(1) nger guard is supplied with each BCV-980. Several nger guards

are available depending on tube OD

STORAGE AND HANDLING

Storage condions

Store the product under packed condions in an an-stac bag. The storage place shall be free from moisture, mechanical shock

and vibraon. The ambient temperature shall be between 3°C and 60°C and the humidity between 5% and 80% R.H. without

condensaon

Unpacking and Product Inspecon

On delivery, check the product for damage. Conrm that the model code on the label matches the specicaon in the purchase

order.

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SAFETY CAUTIONS

The BCV-980 is a Pinch Valve: use care keeping ngers, etc. out of the

pinch mechanism! Severe & painful damage is possible.

DIMENSIONAL DRAWINGS: BCV-980

For Reference Only

BCV-980; general arrangement

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Performance Specicaons

Fluid Temperature 4° – 60°C *

Ambient: Temperature/Humidity 0° – 40°C / 30% – 80% RH, non-condensing

Maximum Expected Operang Pressure 6 bar (g)

Dierenal Pressure range 0 - 6 bar

Power Supply Input 24 Vdc 10%

Current Consumpon 4 A max, 1A typical

Alarm Signals Max 30 Vdc, 200 mA NPN open collector

Signal Out (Valve Posion) 4 - 20 mA

Weed Parts None

Non Weed Parts, Enclosure Non-magnec 316L Stainless Steel,

Non-magnec Powder-coated Stainless Steel

Mounng Orientaon Performance unaected by mounng orientaon

Fluid Connecons 1/8” – 1” ID exible tube, braided or un-braided

Ingress Rang IP65

Panel Mounng Universal thickness — accommodates any panel thickness

Panel Cutout 1/4 DIN (90mm x 90mm)

Mass 2.6 kg – 3.3 kg

* Consult the factory for higher temperature applicaons

* Up to four external analog signals. Implements standalone TFF control

Electrical Specicaons

Material Specicaons

Physical Specicaons

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GETTING STARTED

Unpack and mount the BCV-980, using the included Silicon Sponge Gasket, through a standard ¼ DIN panel cut-out [88mm X

88mm]. Panel or surface mounng is essenal to achieve IP65 ingress protecon. The BCV-980 is fully connectorized using

shielded Hirose connectors. [Hirose connectors are readily available from Digikey, Farnell, Mouser, Newark, and others.] Fully

assembled cables are available. Consult Malema factory for details

FINGER GUARD INSTALLATION:

The FINGER GUARD is packaged separately. Using provided 3/16” Allen wrench and provided PIN SCREWS, install the FINGER

GUARD. Finger ght is adequate.

FINGER GUARD INTERLOCK:

The FINGER GUARD is magnecally interlocked with the BCV-980 crush mechanism. The DRAW BAR will not move unl the

FINGER GUARD is replaced. Various FINGER GUARDS are available depending on the tube size in use. Contact Malema for the

FINGER GUARD(s) required for your applicaons.

POWER, CONTROL & SIGNALING

A male, twelve(12) pin, Hirose connector supports device power along with primary signaling. A twelve(12) core, three(3) meter

long, connectorized cable with stripped ends is provided with each BCV-980.

The BCV-980 accepts up to four(4) external analog signals and provides two(2) discrete, OPEN Collector STATUS / ALARM Outputs

[NPN, 30 VDC, <200 mA], one(1) discrete Input along with two(2) analog Output signals. One(1) of these analog outputs is

proporonal to valve posion and provides CLOSED Loop feedback to a remote controller. The other analog output reports μP

temperatures or alternavely, this output can be ulized to drive other components in your system [i.e.: Pump speed(?), consult

Malema factory for details].

The device communicates over [Malema Addressable Sensor Network] MASN (RS-485 serial). Up to two hundred y(250)

devices can be supported by a single RS-485 master controller. MASN supports viewing & seng of device conguraon along

with near real-me data logging on a customer supplied computer or laptop.

GROUNDING

The four(4) rear mounted 4 mm studs provide for a convenient GROUND or EARTHING connecon.

A thumb nut is provided for this essenal electrical connecon. Failure to properly GROUND the

BCV-980 voids the warranty and CE Compliance.

EXTERNAL SENSORS

If ordered separately, Three(3), female, twelve(12) pin connectorized cables support up to three(3) aached, external sensors.

[These are oen pressure transducers, or ow meters monitoring the condions surrounding a TFF module.] The BCV-980

provides +24 VDC, [up to 100 mA] power to these external sensors and accepts Discrete & Analog signals in return. If ulizing

TFF Mode, these external signals are then ulized, internally by the BCV-980, to modulate valve posion. Addionally, these

external sensor interfaces provide:

• A POWER Cycling capability

•A Zero RESET signal

• Discrete signal “Hand Shaking”

• RS-485 Serial Communicaon based on the Malema Addressable Sensor Network Protocol (MASN):

o Baud Rate = 115,200

o Data Bits = 8

o Parity = NONE

o Stop Bits = 1

o Flow Control = NONE

TUBE SIZE SELECTION

The standard BCV-980 ships pre-linearized for several standard tube sizes. These sizes can be selected from a “drop down” menu

accessible from the Malema GUI.

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TUBE INSTALLATION

Tubing installaon proceeds from the front of the BCV:

1. Ensure the DRAW BAR is OPEN. A remote panel mounted key switch accomplishes this funcon.

2. OPEN the FINGER GUARD

3. Insert the tube-manifold

4. CLOSE the FINGER GUARD

5. RESTORE the key switch to the normal or operate posion

6. The BCV-980 executes an inializaon roune locang the zero(0) ow locaon

7. The BCV-980 is now ready to operate

REMOTE MANIFOLD INSTALL COMMAND

This unit is provided with REMOTE MANIFOLD INSTALL COMMAND. An external +24 VDC signal applied to the DI pin [PIN #8,

WHITE/BLACK] on rear panel mounted connector P0 causes the DRAW BAR to fully OPEN so, manifolding can be easily installed

or removed. When this signal is removed the BCV-980 slowly closes under reduced torque unl motor stall occurs. At this point

a new ZERO posion is established and the system returns to Normal operaon.

The internal circuit for this funcon is shown here:

VALVE LINEARIZATION

The BCV-980 ships with Malema’s linearizaon scheme enabled. The feature can be disabled by unchecking the “Enable LIN

funcon” Check Box in the Bio Control Valve sengs Window of the GUI. A Valve Linearizaon Vs. Flow Rate Procedure is

provided [see page 11] should you require a unique linearizaon result

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PANEL MOUNTING

The BCV-980 panel mounts through a standard ¼ DIN panel cutout [88mm X 88mm].

An ORANGE Silicone Rubber sponge gasket is provided with each BCV-980. When properly installed with the gasket the BCV-980

provides IP65 ingress rang; i.e.: protecon against water jets.

CAUTION: [The front of the

BCV-980 provides IP65. IP30 protecon

is provided for the poron behind the

panel or when not panel mounted.]

GROUNDING:

Any of the four(4), 4 mm Rear Mounng

studs can be used for GROUNDING.

[OPTIONAL, BENCH TOP-MOUNTING]

A clear, blue nt, PVC Bench-Top mounng accessory is available. Consult Malema for details.

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VALVE LINEARIZATION VS. FLOW RATE PROCEDURE

Scope:

To set the BCV angles for minimum and maximum ow rates

Setup requirement:

• PC with GUI to indicate ow rate

• Calibrated Flow meter

• BCV-980 with power/signal cable

• 4-20mA signal generator

• Hose to test

o Use the same tubing / hose that will be used in producon

Procedure:

1. Place the tubing into BCV-980 with no pressure and

power-up the unit

a. On inial POWER-UP the BCV-980 slowly

closes while seeking full closure. This is

automac and requires several seconds.

2. Aer the fully closed point is located, set the BCV

to remote mode.

3. Set maximum valve opening of BCV-980 allowing

maximum ow thru the tube.

4. Establish owrate thru the ow meter equal to 110%

of desired owrate:

a. [i.e.: if 2L max desired; set ow to 2.2L]

5. Slowly decrease the maximum valve opening of the

BCV-980 Valve angle unl the ow meter reported

ow rate is 2L/min

6. Enter this angle value in the GUI Maximum open-

ing eld

7. Connue to decrease the angle unl no ow is

observed

8. Enter this angle value in the GUI Deadband eld

9. Set the BCV to remote operaon mode:

a. The Status LED turns BLUE in Remote mode

420 Max opening [degrees]

120 Deadband [degrees]

10. Hook-up a 4-20ma analog signal generator to the the Analog setpoint input of main power cable

11. Set input setpoint signal to 20ma

a. Conrm the BCV-980 opens to the GUI maximum opening angle

b. Conrm ow rate equals the maximum desired owrate

12. Set setpoint to 4ma

a. Conrm the BCV-980 closes to the GUI Deadband angle

b. Conrm minimum ow rate or pressure observed.

Note: The Deadband angle adjustment is an iterave process

13. Power cycle the unit and verify the setpoint and owrates are correct

14. Record owrates for the following setpoints:

a. 4ma __________

b. 5ma __________

c. 8ma __________

d. 12ma __________

e. 16ma __________

f. 20ma __________

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