USD 2724Instructions For Use

Remote Control of the Palltronic® Flowstar IVIntegrity Test Instrument Using the PROFIBUSuProtocolPart Numbers: FFS04SP, FFS04RP

2

Contents

Safety and Information Symbols ...........................................................................................3

1. Safety Instructions .............................................................................................................3

1.1 Personal Safety ..............................................................................................................3

2. Introduction ........................................................................................................................3

2.1 Key Features and Benefits ............................................................................................4

2.2 Standard Functions ........................................................................................................4

3. Installation ..........................................................................................................................4

3.1 Configuring the PROFIBUS Interface..............................................................................4

3.2 Connecting the Instrument to the PLC ..........................................................................4

3.3 Importing the GSD Description File into the PLC Control Code......................................5

4. Remote Operation using PROFIBUS ...............................................................................5

4.1 Special Considerations Regarding Test Parameters ......................................................6

4.2 Commands Available to the PLC for Remote Control ....................................................6

4.3 Data Available to the PLC from the Palltronic instrument................................................7

4.3.1 Status Codes ........................................................................................................8

4.3.2 Result Codes ........................................................................................................9

4.4 Running a Test on the Palltronic Flowstar IV Instrument ..............................................10

5. Troubleshooting................................................................................................................10

5.1 Preliminary Troubleshooting..........................................................................................10

5.2 Continued Difficulties....................................................................................................11

Appendix A ...........................................................................................................................11

www.pall.com/biopharm 3

Safety and Information Symbols

Safety and information is identified in this instruction manual with the following symbols:

Warning! identifies a dangerous situation where there is a safety risk and personal injury may follow.

Important: identifies a potentially dangerous situation, a risk to the equipment or other importantinformation.

Note: identifies user tips and other useful information.

1. Safety Instructions

Warning! Please read the following instructions carefully and completely before using the PalltronicFlowstar IV instrument with PROFIBUS functionality.

Please also read the Instructions For Use for the integrity test instrument with which the PROFIBUSfunctionality will be used, to ensure safe use under remote control. Document Title Number

Palltronic Flowstar IV Integrity Test Instrument: Instructions For Use USD2594

Please contact your local Pall office or distributor if you require a copy of the latest revision of this document.

1.1 Personal SafetyAppropriate protective clothing should be worn by operators (for example, gloves and safetygoggles) when working with chemicals and compressed gas supplies during filter integrity testing.

The Palltronic Flowstar IV integrity test instrument utilizes compressed air when operated and,therefore, caution is necessary when disconnecting pneumatic connections from the system. It is the operator’s responsibility to ensure that an oil-free regulated gas supply is used.

All pneumatic tubing used for integrity testing should be rated to withstand the gas pressureused (up to 8 barg or 116 psig). The operator should check the tubing and connectors fordamage before each use.

2. Introduction

The PROFIBUS functionality enables a Programmable Logic Controller (PLC) to remotely control theinstrument. The PLC can initiate the standard test functions of the instrument, specify the applicableparameters for the test, monitor the progress of the test and, at the end of the test, receive themeasured test result together with a pass/fail indication (based on the specified test parameters). Theintegrity test results can then be stored by the control unit or high-level Supervisory Control And DataAcquisition (SCADA)1 system, as required. When this information is combined with the SCADAinformation on the filter type, serial number, production area etc. it forms a comprehensive electronicbatch record.

PROFIBUS DP is supported by most PLC manufacturers but may be supplied as an optional modulefor the PLC in use. Please check the level of support for PROFIBUS DP and GSD2 definition files withthe manufacturer of the PLC.1 SCADA: a directory of SCADA packages and information is available at www.scadanews.com

2 GSD: A recognised file format standard to define input and output variables of slave instruments to a PROFIBUS-enabled PLC

4

The GSD file is required to allow integration of the integrity test instrument into the PLC control program,reducing the programming required to control the PROFIBUS instrument to a minimum. This file issupplied on the Universal Serial Bus (USB) flash drive provided with the instrument and is also availablefrom Pall on request.

2.1 Key Features and BenefitsEnd users can use the PROFIBUS functionality to remotely control the instrument via a PLCusing an array of input and output parameters for the various test parameters and commands.The system calls the instrument to perform a prescribed test and the system receives theresults at the end of the test. The main benefits are minimized operator involvement, integrationof the instrument into the normal operation of the plant and the incorporation of the test resultsinto the batch records.

2.2 Standard FunctionsThe PROFIBUS functionality enables the PLC to start the following standard functions of thePalltronic integrity test instrument:

• Self Test (ST)

• Forward Flow Test (FF)

• Bubble Point Test (BP)

• Water Intrusion Test (WIT)

• Leak Test (LT)

• Pressure Decay Test (PD)

In order to perform a combined Forward Flow and Bubble Point test (FF+BP), the PLC mustrun a Forward Flow test and then, on completion follow it with a Bubble Point test if required.

3. Installation

Important: The PROFIBUS functionality must only be used with the corresponding Palltronic integritytest instrument. A PROFIBUS DP module is required on the PLC for communication across thePROFIBUS DP network. Installation should only be carried out by a suitably qualified systems engineer.

3.1 Configuring the PROFIBUS InterfaceImportant: The instrument and PLC must both be switched off before any attempt is made toconnect them.

The PROFIBUS interface inside the instrument utilizes a Unigateu PROFIBUS DP gateway in ‘slave’mode. No configuration is required except for the Palltronic Flowstar instrument address. The BUSaddress can be set from the system “Configuration”, “Advanced settings” and “Automation”.

3.2 Connecting the Instrument to the PLCUse a PROFIBUS communication cable (not included) to connect the PLC to the “BUS” socketlocated at the rear of the instrument.

Figure 1Connectors on the Rear of the Instrument

1 = Power ON/OFF

2 = Power connection

3 = Ethernet (RJ45)

4 = USB

5 = RS232

6 = CAN Bus (Controller Area Network Bus) (Pall use only)

7 = PROFIBUS or DeviceNetu

The pin description for the 9-pin PROFIBUS socket is as follows:

Table 1PROFIBUS Pin Descriptions

Pin Description

9-pin female socket 1 not connected

2 not connected

3 B (non-inverting RxD/TxD signal)

4 CNTR-P (repeater control signal)

5 M5 (DGND – data ground; reference for P5)

6 P5 (5V DC supply voltage)

7 not connected

8 A (inverting RxD/TxD signal)

9 not connected

3.3 Importing the GSD Description File into the PLC Control CodeThe USB flash drive supplied with the instrument contains the GSD file for the integrity test instrument.

The method for incorporation of the appropriate GSD file into the PLC control program isdependent on the PLC and programming software in use. Please consult the PLC user manualfor further information and guidance.

4. Remote Operation using PROFIBUS

Note: Configuring or creating a PLC control program incorporating the instrument with PROFIBUSfunctionality is beyond the scope of this document, and as such should only be carried out by a suitablyqualified programmer.

www.pall.com/biopharm 5

5 4 3 2 1

9 8 7 6

6

4.1 Special Considerations Regarding Test ParametersThe PROFIBUS functionality allows the PLC to transfer test parameters to the instrument inorder to specify and run integrity tests. As the test is controlled remotely, only the testparameters mandatory for running the test are supported (i.e. test pressure, test time,maximum flow rate or minimum bubble point – as appropriate to the type of test). Otherinformation (e.g. product name, batch number, filter type, etc) should be collated on the PLC or higher-level SCADA system and cannot be transferred to the instrument over the PROFIBUSinterface. Similarly, no data stored on the instrument can be read by the PLC, including storedtest results and test programs.

Important: The instrument will perform syntax and data type error checking only (see Section4.3.2 for details on these error codes) but will not perform validity checks on parametersreceived. If a parameter is set outside the range of the instrument, no error will be generatedbut the test may not start.

When operated remotely, the instrument can only accept pressure settings in millibar. The PLCprocess software should convert all pressure parameters to millibar (mbar) using the followingconversion factors:

1 psi = 68.94757 mbar

1 kp/cm2 = 980.6650 mbar

1 kPa = 10 mbar

However, the interface does not allow for non-integer numerical data. Therefore, although testpressures sent to the instrument must be in millibar, the maximum test flow parameter must bespecified in micro-liters per minute (µL/min), the minimum flow parameter must be specified inmicro-liters per minute (µL/min), the maximum pressure decay parameter in micro-bar (µbar)and the module factor as (factor value x 1000) (e.g. 0.5 must be entered as 500).

Similarly, measured flow is reported back in µL/min and measured bubble point or pressuredecay in µbar:

1 mL/min = 1000 µL/min (flow)

1 mbar = 1000 µbar (pressure)

4.2 Commands Available to the PLC for Remote ControlThe following parameters are provided to allow the PLC to remotely control the Palltronicintegrity test instrument. These ‘output’ parameters are write-only; see Section 4.3 forinformation on the ‘input’ data that can be used to monitor the status of the instrument andrecord the final test result.

Table 2Commands Available to the PLC

Parameter Name Offset Description Data Type3

TestCmd1 +0 Test control register, bit-field defined as follows:1 Bytebit 0 Start filter test

bit 1 Abort filter test

bit 2 Request system information2

bit 5 Lock touchscreen

bit 6 Unlock touchscreen

TestCmd2 +1 Communication control register, bit-field defined as follows1 Bytebit 0 Start communication

bit 1 Stop communication

www.pall.com/biopharm 7

Table 2 ContinuedCommands Available to the PLC

Parameter Name Offset Description Data Type3

TestModeIn +2 Test type, defined as follows: Word

1 Forward Flow Test (FF)

2 Water Intrusion Test (WIT)

3 Bubble Point Test (BP)

4 Self Test (ST)

5 Leak Test (LT)

6 Pressure Decay Test (PD)

TestPressure +4 Test pressure in mbar (FF, WIT, LT, PD only) Word

Minimum bubble point in mbar (BP only)

TestTime +6 Test time in seconds (FF, WIT, LT, PD only) Word

TestMaxFlow +8 Maximum flow in µL/min (FF, WIT, LT only) Long

Max Pressure Decay in µbar (PD only)

TestExtra1 +12 Minimum flow in µL/min (FF only) Long

Module factor in (x 1000) (BP only)

TestExtra2 +16 Maximum pressure in mbar (BP only) Word

Stabilization time in seconds (PD only)

TestPrestabPress +18 Pre-stabilization pressure in mbar Word(the function must be activated in the instrument configuration)

TestPrestabTime +20 Pre-stabilization time in seconds (0 = off) Word(the function must be activated in the instrument configuration)

TestDownPress +22 Max. downstream pressure in mbar Word(the function must be activated in the instrument configuration)

1 The bit commands in “TestCmd1” and “TestCmd2” are triggered by the rising edge of the signal. The bit must be resetafter use, once the CmdDone bit of the test control feedback register is set (see Section 4.3).

2 System information consists of the instrument serial number, software version and calibration date.

3 The integrity test instrument uses three data types. See Appendix A.

4.3 Data Available to the PLC from the Palltronic instrumentThe following data fields are provided to allow the PLC to monitor the status of the instrument.These ‘input’ parameters are read-only; see Section 4.2 for information on the ‘output’parameters that can be used to control the operation of the instrument.

Table 3Data Available to the PLC

Parameter Name Offset Description Data type1

Done +0 Test control feedback register, bit-field defined as follows: Bytebit 0 CmdDone (set on completion of TestCmd1)

Mode +1 Test type confirmation, defined as follows:1 Byte0 Error in test parameters (see Section 4.3.2)

1 Forward Flow Test (FF)

2 Water Intrusion Test (WIT)

3 Bubble Point Test (BP)

4 Self Test (ST)

5 Leak Test (LT)

6 Pressure Decay Test (PD)

8

Table 3 ContinuedData Available to the PLC

Parameter Name Offset Description Data *type*

Status +2 Current test status of the instrument – see Section 4.3.1 Word

Result +4 Test result from the instrument – see Section 4.3.2 Word

Measure +6 Actual measured flow rate (µl/min), bubble point (µbar) or Long pressure decay (µbar)

SerNo +10 Serial number of instrument Long

AqSerNo +14 Not used Long

VerVK +18 Instrument software version – leading digit, e.g. 3.2d Byte

VerNK +19 Instrument software version – second digit, e.g. 3.2d Byte

VerB +20 Instrument software version – letter, e.g. 3.2d Byte(letter will be displayed in ASCII code [e.g. d = 100])

VerSpec +21 Instrument software version – special, e.g. 3.2c 0010 Word

CalDateDD +23 Calibration date – day, e.g. 24/10/04 Byte

CalDateMM +24 Calibration date – month, e.g. 24/10/04 Byte

CalDateYY +25 Calibration date – year, e.g. 24/10/04 Byte

Lifebeat +26 Watchdog timer; increased once per second while Byte communication between the instrument and PLC is active

1 The integrity test instrument uses three data types. See Appendix A.

4.3.1 Status CodesThe “Status” output codes give the current status of the instrument. Possible values are:

Table 4Status Output Codes

“Measure” field valid?

Status Description Flow Pressure Test*

1 Not used ✖ ✖

2 Instrument is idle, waiting for input ✖ ✖

3 Instrument is printing the test printout ✖ ✖

8 Pre-stabilization phase is active ✖ ✖ FF, WIT, LT, BP

9 Vent phase active ✖ ✖

10 Not used ✖ ✖

11 Self test is active ✖ ✖ ST

12 Instrument is pressurizing ✖ ✖ FF, WIT, LT, PD, BP

13 Instrument is in stabilization phase FF only ✖ FF, WIT, LT, PD

14 Instrument is in FF-test phase ✔ ✖ FF

15 Instrument is in WIT-test phase ✔ ✖ WIT

16 Instrument is in BP-test phase ✖ ✔ BP

19 Instrument is in FC-test phase not obtainable via remote control

21 Instrument is in LT-test phase ✔ ✖ LT

Table 4 ContinuedStatus Output Codes

“Measure” field valid?

Status Description Flow Pressure Test*

22 Instrument is in PD-test phase ✖ ✔ PD

81 Wet clean is active ✖ ✖

82 Air clean 1 is active ✖ ✖

83 Air clean 2 is active ✖ ✖

4.3.2 Result CodesWhen the “Mode” variable is non-zero, then the test parameters on the instrumentwere specified correctly and the possible “Result” output codes are:

Table 5Result Output Codes

“Measure” field valid?

Result Description Flow Pressure Test*

0 Instrument is active† ✔ FF, WIT

or no test has been run (when “Status” = 2) ✔ BP

1 Internal error ✖ ✖

2 “Line pressure too low” ✖ ✖ FF, WIT, BP, LT, PD

3 “Pressure not obtainable” (pressurizing phase) ✖ ✖ FF, WIT, BP, LT

4 “Line Pressure Unstable” ✖ ✖ FF, WIT, LT

5 “Flow too high” ✖ ✖ FF, WIT, LT

6 “Flow too low” ✖ ✖ FF, WIT, LT

7 “Flow within limits” – test passed ✔ ✖ FF, WIT, LT(actual flow < max)

8 “Flow outside limits” – test failed ✔ ✖ FF, WIT, LT(actual flow > max)

9 “Manual abort” ✖ ✖

10 “Flow measurement unstable” ✖ ✖ FF, WIT, LT(measurement phase)

11 not used ✖ ✖

12 “BP within limits” – test passed ✖ ✔ BP(bubble point > min)

13 “BP outside limits” – test failed ✖ ✔ BP(bubble point < min)

14 “BP not obtainable” – pressure not obtainable ✖ ✖ BP

15 “Self test passed” ✖ ✖ ST

16 “Self test failed” ✖ ✖ ST

17 not used ✖ ✖

18 not used ✖ ✖

24 “Downstream pressure too high” ✖ ✖

www.pall.com/biopharm 9

10

Table 5 ContinuedResult Output Codes

“Measure” field valid?

Result Description Flow Pressure Test*

25 “Maximum pressure reached” ✖ ✖ BP

26 “No Leak detectable” – test passed ✖ ✖ LT

30 “Pressure Decay within limits” – test passed ✖ ✔ PD

31 “Pressure Decay outside limits” – test failed ✖ ✔ PD

32 BP “leak test failure” – test failed ✖ ✖ BP

33 “Pressure increase detected” – test failed ✖ ✔ PD

34 Low flow alert – test passed ✖ ✖ FF

35 “Setup error” ✖ ✖

40 “Ext. PT Error” (Downstream PT not connected) ✖ ✖

41 “Ext. valve Error” (External vent valve ✖ ✖not connected)

* The “Test” column indicates specific events that only occur in certain tests; a blank entry indicatessystem-wide events. It is meant as a guide to likely events that can occur during a test process, but is not exclusive.† While a FF, WIT or BP test is in the measurement phase the “Measure” field contains the currentmeasured value for monitoring purposes (see Section 4.3.1).(Quotes indicate instrument message in UK English)

4.4 Running a Test on the Palltronic Flowstar IV InstrumentNote: In order to ensure correct operation, the PROFIBUS interface must be functioningcorrectly and the Palltronic instrument must be switched on and showing the ‘Main Menu’screen before executing the following sequence. This may require operator intervention.

Set “TestModeIn” to the required test method and supply the test parameters “TestPressure”,“TestMaxFlow” (not required for a Bubble Point test) and “TestTime” as applicable to the test.

Set bit 0 of “TestCmd1” to initiate the test on the instrument. When bit 0 of “CmdDone” is set inresponse, clear bit 0 of “TestCmd1”.

The instrument will start the test sequence. The serial number (“SerNo”), software version(“Ver*”) and calibration date (“CalDate*”) are also read from the instrument and are available to the PLC.

The “Result” parameter will show ‘0’ indicating the test is active and “Status” will reflect thecurrent phase of testing, or if “Mode” is ‘0’ then an error has occurred and “Result” will showthe appropriate error code.

When “Status” shows ‘2’, the instrument has completed the test. “Result” will show theapplicable end result and “Measure” will hold the measured value. See Section 4.3.2 for detailson the result codes and the contents of the “Measure” parameter.

5. Troubleshooting

5.1 Preliminary TroubleshootingIf any difficulties are experienced with communication, please try the following:

• Check that the Palltronic instrument is correctly connected to the PROFIBUS module on the PLC

• Check that the correct PROFIBUS instrument address has been selected on the Palltronicinstrument and that the PLC is set to recognize this address

• Check that the test parameters used are within the valid ranges of the Palltronic instrument(see the instrument “Instruction For Use” document listed in Section 1)

5.2 Continued DifficultiesIf following the steps in Section 5.1 has not solved the problem or additional technical supportis required (available as a charged service), please contact your local Pall office or distributor.Supplying a detailed written description of the problem will facilitate a quick response.

Appendix A

Table 6PROFIBUS Data Types Available

Data type Description

Byte 8-bit unsigned integer

Word 16-bit unsigned integer

Long 32-bit unsigned integer

The ‘Word’ and ‘Long’ data types are ‘big-endian’, i.e. the most significant byte appears in the first memorylocation and the least significant byte appears last. For example, long integer ’12 34 56 78’ would be storedwith ‘12’ in memory offset +0, ‘34’ in memory offset +1, ‘56’ in memory offset +2 and ‘78’ in memory offset +3.

Note: Conversion may be necessary if the PLC does not support big-endian data.

www.pall.com/biopharm 11

Europe+41 (0)26 350 53 00 phone+41 (0)26 350 53 53 faxLifeSciences.EU@pall.com E-mail

United States800.717.7255 toll free (USA)516.484.5400 phone516.801.9548 faxbiopharm@pall.com E-mail

International OfficesPall Corporation has offices and plants throughout the world in locations such as: Argentina, Australia, Austria,Belgium, Brazil, Canada, China, France, Germany, India, Indonesia, Ireland, Italy, Japan, Korea, Malaysia, Mexico,the Netherlands, New Zealand, Norway, Poland, Puerto Rico, Russia, Singapore, South Africa, Spain, Sweden,Switzerland, Taiwan, Thailand, the United Kingdom, the United States, and Venezuela. Distributors in all major industrial areas of the world.

The information provided in this literature was reviewed for accuracy at the time of publication. Product data may besubject to change without notice. For current information consult your local Pall distributor or contact Pall directly.

© 2010, Pall Corporation. Pall, and Palltronic are trademarks of Pall Corporation. ® indicates a trademarkregistered in the USA. Filtration. Separation. Solution.SM is a service mark of Pall Corporation. uUnigate is atrademark of Deutschmann Automation GmbH. PROFIBUS is a trademark of PROFIBUS & Profinet International.DeviceNet is a trademark of Open DeviceNet Vendors Association (ODVA).

06/10, PDF, UK GN10.3801 USD 2724

Visit us on the Web at www.pall.com/biopharmE-mail us at biopharm@pall.com

ContentsSafety and Information Symbols1.Safety Instructions1.1Personal Safety

2.Introduction2.1Key Features and Benefits2.2Standard Functions

3.Installation3.1Configuring the PROFIBUS Interface3.2Connecting the Instrument to the PLC3.3Importing the GSD Description File into the PLC Control Code

4.Remote Operation using PROFIBUS 4.1Special Considerations Regarding Test Parameters4.2Commands Available to the PLC for Remote Control4.3Data Available to the PLC from the Palltronic instrument4.3.1Status Codes4.3.2Result Codes

4.4Running a Test on the Palltronic Flowstar IV Instrument

5.Troubleshooting5.1Preliminary Troubleshooting5.2Continued Difficulties

Appendix A