Malema BCV-980 User manual

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Corporate Headquarters West Coast Headquarters Asia Pacic Headquarters
1060 S Rogers Circle
Boca Raton, FL 33487
P: [phone] F: [phone]
2329 Zanker Road
San Jose, CA 95131
P: [phone] F: [phone]
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
3
© 2020 Malema Engineering Corporaon. All rights reserved.
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
4
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
5
BCV-980; general arrangement

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6
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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8
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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9
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
10
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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Typical Linearizaon Results
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12
Connector PINOUTS
Connector FUNCTIONS:
MAIN POWER / CONTROL CONNECTOR [twelve(12) Pin, Male]:
1. RED +24 VDC ±10%; POWER INPUT; 2 AMP
2. BLACK WARNING OUT; OPEN COLLECTOR
3. PINK ALARM OUT; OPEN COLLECTOR; this line shorts to GROUND in the event of drive motor stall.
4. GRAY DIGITAL OUTPUT; FINGER GUARD OPEN
5. BLUE RS485 A+; serial communicaons ulizes Malema Addressable Sensor network protocols;
up to two hundred y(250) devices can be supported on a single channel
6. WHITE RS-485 B-
7. RED / BLACK SETPOINT INPUT; a congurable analog INPUT VIA the Malema
GUI ; could be 4 to 20 mA; 0 to 5 VDC; 0 to 10 VDC or 1 to 5 VDC
8. WHITE / BLACK DIGITAL INPUT 0; A +24 VDC signal applied to this PIN implements the REMOTE MANIFOLD INSTALL
COMMAND [see line 132 on page 7 of this USER GUIDE]
9. YELLOW ANALOG OUT 1; An analog output signal proporonal to valve posion, 4 mA = valve
closed, 20 mA = valve fully opened.
10. BROWN ANALOG OUT 2; Analog output signal proporonal to μP temperature2 ; 4 mA = 0oC,
20 mA = 100o C; could be congured to mirror one(1) of the remote sensor inputs or some calculated value
11. GREEN GROUND
12. VIOLET GROUND
1Congurable VIA the Malema GUI; default is 4 to 20 mA; other opons 0 to 5 VDC; 0 to 10 VDC or 1 to 5 VDC
2This signal can be repurposed – consult Malema for details

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13
REMOTE SENSOR CONNECTORS [i.e.: RP 1; RP 2 and RP 3] [twelve(12) Pin, Female]:
1. RED +24 VDC ±10%; POWER INPUT; 1 AMP
2. BLACK REMOTE POWER; +24 VDC ±10%; 0.100 AMP; these circuits are
controlled by the BCV-980 allowing interrupon or POWER Cycling of connected sensors
3. PINK DIGITAL OUTPUT 1 thru DIGITAL OUTPUT 3; these are OPEN COLLECTOR circuits enabling the BCV
to send command signal to aached sensors; unimplemented
4. GRAY ZERO 1 thru ZERO 3; these signals allow the BCV-980 to force a ZERO funcon for remote
sensors; these signals are congurable in rmware either supplying +24 VDC or GROUND as required by the
remote sensors
5. BLUE RS485 A+; serial communicaons; ulizes Malema Addressable Sensor network protocols;
up to two hundred y(250) devices can be supported on a single channel
6. WHITE RS-485 B-
7. RED / BLACK ANALOG INPUT 1 thru ANALOG INPUT 3 [or SUPPLY, RETENTATE or PERMEATE]; congurable analog
signal carrying the values generated by the remote sensors
8. WHITE / BLACK DIGITAL INPUT 1 thru DIGITAL INPUT 3; these signals allow the remote sensors to report ALARM
or FAULT condions to the BCV-980
9. YELLOW RESERVED
10. BROWN RESERVED
11. GREEN GROUND
12. VIOLET GROUND
3Requires custom rmware – consult Malema for details

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14

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15
CABEL DETAILS

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FRONT PANEL STATUS DISPLAY
16
The front panel of the BCV-980 supports two(2) LEDs:
•POWER – This LED glows when adequate 24 VDC power is applied.
LED color changes based on currently selected operang mode:
o BLUE – Remote Mode
o GREEN – TFF Mode
•CLAMP – The CLAMP LED glows RED when the FINGER GUARD is OPEN
or missing. At these mes all operang modes are disabled. To restore
funcon replace & CLOSE the FINGER GUARD.

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17
TYPICAL, STAND-A-LONE, TFF APPLICATION

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Malema has manufactured Liquid Flow Controllers for many years. Over this me, we have developed sophiscated, propri-
etary, expert, self-learning, rule based, PID control algorithms. These algorithms overcome the shortcomings typically found in
PID process control.
Quick responses to process upsets or changing condions are not followed by overshoot, undershoot and delays associated with
quarter wave decay. Malema ow controllers typically achieve stable control in less than one(1) second aer a process upset
or step change in control setpoint. Systems have normal responses to these events. By observing and recognizing these dis-
rupons as they occur, Malema ow control algorithms take the appropriate steps early on, reestablishing and restoring control
quickly. Just like a truck driver in the mountains knows to conserve his brakes and momentum as he descends so, he’ll need less
addional energy ascending the next hill.
18
CONTROL STRATEGY
Copy the Malema Sensors applicaon from the CD to a local drive and create shortcut to desktop.
Open the Malema applicaon, click on the text eld labeled with the COM port number to connect PC app to BCV-980 located
in the upper right-hand corner.
To capture a graph, check the Collect data checkbox.
Graph below shows Posion and Setpoint with ramp up/down of 500 deg.
MALEMA GUI

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Using the GUI to control Digital setpoint:
• Connect the RS485 to the cable.
• Open the Bio Control Valve Sengs tab.
• Set the control mode to Remote.
• Click checkbox “Motor ON”.
• Enter a value in degrees or percent to the Digital setpoint window.
• Click the “Use % for Setpoint and posion” if entering percent valve.
• Click on Update parameter sengs buon.
Note: Update parameter sengs buon must be clicked when any seng has changed.
Controlling the Valve using 4-20mA analog signal:
• Hook up the 4-20mA connecons to the command signals of control cable provided.
• Set the control mode to Remote.
• Click checkbox “Check to use analog setpoint”.
• Select Setpoint input type: 4-20mA, 1,5V, 0-5V, or 0-10V.
Using TTF mode:
• Set the control mode to TFF.
• Connect the other inputs.
• Select the input type for each input: 4-20 mA, 1,5 V, 0-5 V, or 0-10 V.
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Bio Control Valve sengs Window
GUI CONTROL WINDOW