Aalborg SDPROC Operating Manual

OPERATING MANUAL

SDPROC COMMAND

MODULES

Technical Data Sheet No. TD9704M Rev F Date of Issue: August 2010

Aalborg7is a registered trademark of Aalborg Instruments & Controls.

NOTE: Aalborg reserves the right to change designs and dimensions at its sole

discretion at any time without notice. For certified dimensions please contact Aalborg

TABLE OF CONTENTS

(a) UNPACKING THE SDPROC COMMAND MODULE.......................................

a.1 Inspect Package for External Damage........................................................

a.2 Unpack the Command Module...................................................................

a.3 Returning Merchandise for Repair...............................................................

(b) INSTALLATION.............................................................................................

b.1 Location of Installation................................................................................

b.2 Electrical Connections.................................................................................

b.2.1 Connecting Flow Transducers.....................................................................

b.2.2 Power Input...............................................................................................

b.2.3 Applying Power to the SDPROC.................................................................

b.2.4 Remote Signal Interface.............................................................................

b.2.5 Relays Interface............................................................................................

(d) SPECIFICATIONS..........................................................................................

d.1 CE Compliance..............................................................................................

(e) OPERATING INSTRUCTIONS........................................................................

e.1 Preparation and Warm Up..........................................................................

e.2 Single Channel SDPROC.............................................................................

e.2.1 Start up Display..........................................................................................

e.2.2 Main Display...............................................................................................

e.2.3 Control Mode Status..................................................................................

e.2.4 Set Point Display..........................................................................................

e.2.5 Totalizer / Alarm Display..............................................................................

e.2.6 Setup Channel Display................................................................................

e.2.6.1 Internal/External/Program Reference..........................................................

e.2.6.2 Setup Gas Density Display.........................................................................

e.2.6.3 Setup Engineering Units Display................................................................

e.2.6.4 Setup Full Scale Flow Rate Display............................................................

e.2.6.5 Setup Relays Assignment Display..............................................................

e.2.7 Setup Alarm Display.....................................................................................

e.2.7.1 Setup Alarm Mode Display.........................................................................

e.2.7.2 Setup Alarm Low Display...........................................................................

e.2.7.3 Setup Alarm High Display...........................................................................

e.2.7.4 Setup Alarm Delay Display..........................................................................

e.2.7.5 Setup Alarm Action Display........................................................................

e.2.8 Setup Totalizer Display..................................................................................

e.2.8.1 Setup Totalizer Mode Display.....................................................................

e.2.8.2 Setup Totalizer Start Flow Display..............................................................

e.2.8.3 Setup Totalizer Stop Volume Display..........................................................

e.2.8.4 Setup Totalizer Action Display....................................................................

1 1 1 1

1 1 2 2 3 3 3 4

4 5

6 6 6 6 6 7 7 8 8 9 9 10 10 10 11 11 11 11 12 12 12 13 13 13 13

e.2.9 Program Settings Display............................................................................

e.2.9.1 Batch Program Settings Display.................................................................

e.2.9.2 Timer Program Settings Display.................................................................

e.2.10 Status Check...............................................................................................

e.3 Multi Channel SDPROC...................................................................................

e.3.1 Start up Display............................................................................................

e.3.2 Main Display...................................................................................................

e.3.3 Channel Select...............................................................................................

e.3.4 Set Point Display............................................................................................

e.3.5 Control Mode Display.....................................................................................

e.3.6 Totalizer/Alarm Status Display.......................................................................

e.3.7 Setup Channel Display....................................................................................

e.3.7.1 Internal/External/Program Reference..........................................................

e.3.7.2 Setup Gas Density Display.........................................................................

e.3.7.3 Setup Engineering Units Display.................................................................

e.3.7.4 Setup Full Scale Flow Rate Display.............................................................

e.3.7.5 Setup Relays Assignment Display...............................................................

e.3.8 Setup Alarm Display.......................................................................................

e.3.8.1 Setup Alarm Mode Display..........................................................................

e.3.8.2 Setup Alarm Low Display............................................................................

e.3.8.3 Setup Alarm High Display...........................................................................

e.3.8.4 Setup Alarm Delay Display..........................................................................

e.3.8.5 Setup Alarm Action Display.........................................................................

e.3.9 Setup Totalizer Display...................................................................................

e.3.9.1 Setup Totalizer Mode Display......................................................................

e.3.9.2 Setup Totalizer Start Flow Display...............................................................

e.3.9.3 Setup Totalizer Stop Volume Display...........................................................

e.3.9.4 Setup Totalizer Action Display.....................................................................

e.3.10 Program Settings Display.............................................................................

e.3.10.1 Batch Program Settings Display.................................................................

e.3.10.2 Timer Program Settings Display.................................................................

e.3.10.3 Ratio Program Settings Display.................................................................

e.3.11 All Valves Control.........................................................................................

e.3.12 Real Time Clock Settings..............................................................................

e.3.13 Status Check.................................................................................................

(f) MAINTENANCE...........................................................................................

(g) ADC/DAC CALIBRATION PROCEDURES.....................................................

g.1 Digital to Analog (D/A) Slope Calibration..........................................................

g.2 Analog to Digital (A/D) Calibration..............................................................

(h) RS-232 SOFTWARE INTERFACE COMMANDS............................................h.1

h.1 General.........................................................................................................

h.2 Commands Structure..................................................................................

h.3 ASCII Commands........................................................................................

14 14 16 17 17 17 18 18 19 19 19 20 20 21 21 21 22 22 22 23 23 23 23 24 24 24 25 25 25 26 27 28 30 31 31

32 33 34

35 35 35 37

(i) NETWORK COMMUNICATION INTERFACE (OPTIONAL)..............................

i.1 0Base-T RJ-45 Pinout................................................................................

i.2 Network Protocols......................................................................................

i.2.1 DHCP..........................................................................................................

i.2.2 DNS.............................................................................................................

i.2.3 IP Address..................................................................................................

i.3 Configuration....................................................................................................

i.4 Operation Using the SDPROC Web Page.........................................................

i.5 Operation Using the SDPROC Telnet Console..................................................

(j) TROUBLESHOOTING........................................................................................

j.1 Common Conditions........................................................................................

j.2 Troubleshooting Guide....................................................................................

j.3 Technical Assistance.......................................................................................

APPENDIX 1 COMPONENT DIAGRAM.................................................................

APPENDIX 2 DIMENSIONAL DRAWINGS............................................................

APPENDIX 3 WARRANTY....................................................................................

42 42 42 42 43 43 43 44 45

46 46 47 47

(a) UNPACKING THE SDPROC COMMAND MODULE

a.1 Inspect Package for External Damage

Your SDPROC Command Module was carefully packed in a sturdy cardboard carton, with anti static cushioning materials to withstand shipping shock. Upon receipt, inspect the package for possible external damage. In case of external damage to the package contact the shipping company immediately.

a.2 Unpack the Command Module

Open the carton carefully from the top and inspect for any sign of concealed shipping damage. In addition to contacting the shipping carrier please forward a copy of any damage report to your distributor or Aalborg7 directly.

When unpacking the instrument please make sure that you have all the items indicated on the Packing List. Please report any shortages promptly.

a.3 Returning Merchandise for Repair

Please contact the customer service representative of your distributor or Aalborg7 if you purchased the equipment directly, and request a Return Authorization Number (RAN). Equipment returned without an RAN will not be accepted. Aalborg7 reserves the right to charge a fee to the customer for equipment returned under warranty claims if the instruments are tested to be free from warranted defects.

Shipping charges are borne by the customer. Equipment returned “collect” will not be accepted!

It is mandatory that any equipment returned for servicing be purged and neutralized of any dangerous contents including but not limited to toxic, bacterially contagious, corrosive or radioactive substances. No work shall be performed on a returned product unless the customer submits a fully executed, signed SAFETY CERTIFICATE. Please request form from the Service Manager.

(b) INSTALLATION

See AFM/AFC/GFM/GFC/DFC manual for specific instructions on the use and operation of the mass flow meter or mass flow controller transducers.

b.1 Location of Installation

Set the SDPROC in a location where it will be used. This should be a stable surface. Avoid exposing the SDPROC to damaging heat radiation from sunlight or heaters. Avoid vibration and protect the product from moisture or aggressive chemical vapors.

b.2 Electrical Connections

b.2.1 Connecting Flow Transducers

Attach the 15 pin “D” connector cable(s) between the interface panel on the rear of the SDPROC and the Flow Meter/Controller transducer(s). (Number of channels will vary from one to four in accordance with configuration and options purchased.)

Figure b-1, Interface Panel for SDPROC.

No connection with the DATA IN/OUT, RELAYS or RS 232 connector is required for operating the system. However, it may be desirable to perform remote monitoring or control of the flow transducers. In this case, see the pin out chart for the “DATA IN/OUT” connector in step b.2.4.

 Important Notes:

Assure that the “Flow Transducer” cables are used in accordance with configuration and options purchased.

In general, “D” Connector numbering patterns are standardized. There are, however, some connectors with nonconforming patterns and the numbering sequence on your mating connector may or may not coincide with the numbering sequence shown in our pin configuration table above. It is imperative that the appropriate wires are matched in accordance with the correct sequence regardless of the particular numbers displayed on your mating connector, see the pin out chart for the “Flow Transducers” connector.

Power must be shut OFF when connecting or disconnecting any cables in the system.

Cable lengths for Flow Transducers and DATA IN/OUT may not exceed 9.5 feet (3 meters).

Use of the SDPROC in a manner other than that specified in this manual or in writing from Aalborg7, may impair the protection provided by the equipment.

Figure b-2, Pin out chart for CHANNEL l/2/3/4 “Flow Transducers” connector.

b.2.2 Power Input

Make sure the POWER switch on the back of the SDPROC is OFF. On one end of the AC line cord is a universal connector that will fit securely into the AC inlet receptacle at the rear of the SDPROC. Make this connection. Per your specifications at the time of your order, on the opposite end of the AC line cord is a plug compatible with the AC power receptacle you intend to use for AC power supply. Make this connection to the AC power supply receptacle. The SDPROC is capable of receiving 85VAC to 240VAC and 50/60Hz power without any need for jumpering or compensation.

 Use only the AC power line cord supplied with the instrument. Do not attempt to

force or manipulate the plugs of the AC line cord in any way. If it does not fit easily and securely, contact your distributor or Aalborg7.

b.2.3 Applying Power to the SDPROC

Turn the POWER switch to the ON position. A start up display will be briefly visible, and will display the type of SDPROC configuration for the given unit. See the OPERATING INSTRUCTIONS section of this manual for details on controls and displays.

b.2.4 Remote Signal Interface

At the rear of the SDPROC, there is a 25 pin Female Type “D” connector “DATA IN/OUT”. The pin outs are as follows, (NOTE: “External Set Point Reference” is only applicable to mass flow controllers).

Turn the POWER OFF when not in use.

At the rear of the SDPROC, there is a 25 pin Male Type “D” connector “RELAYS”. The pin outs are as follows:

b.2.5 Relays Interface

Microprocessor driven digital Command Modules are used in conjunction with any analog or digital mass flow meters or controllers with 0-5 Vdc input /output signals. One, two, three and four channel Command Module configurations are available. Command Modules contain appropriate power supplies, 24x2 alpha-numeric dot matrix display readout, and four panel buttons which provide complete control over all the various functions necessary to measure and/or control flow. All channels may be simultaneously monitored from output signals to a data aquistion or external monitoring device. RS-232 serial communication interface is standard for all models and supported via a 9 pin “D”-connector at the back panel of the Command Module. RS-232 Software interface commands set allows communications with the unit using either a custom software program or a “dumb terminal” and provide complete control over all modes and functions. Optional built-in Ethernet interface allows accessing any Internet-connected SDPROC from a browser on your work station, PC, or laptop computer. Regardless of where you are, your Command Module is as close as the near- est browser! There are two levels of Web-based Remote Controls: HTML web server and TELNET. The flow set points, measured gas flow and associated totalizer data are scaled directly in engineering units via front panel keypad, RS-232 or Ethernet interface. The following units of measure are supported: %F.S., SLPM, SLPH, SCCM, SCCH, SCFM, SCFH, SCMM, SCMH, LBPM, LBPH, GRPM, GRPH (NOTE: In order to use mass based engineering units proper value of the gas density has to be set for corresponding channel).

(d) SPECIFICATIONS

ENVIRONMENTAL (PER IEC 664): Installation Level II; Pollution Degree II

POWER SUPPLY: 85 to 264 VAC (47 to 63 Hz) 2A max.

FUSE: 2A on input and output power line. When changing, unplug the device from power source. Replace only with fuse 5mm 2A/250V FF.

DISPLAY: 24x2 LCD dot matrix with backlight; 24x2 Vacuum Florescent display optional.

READINGS: 0 to 100% scale is standard; the following units of measure are supported: %F.S., SLPM, SLPH, SCCM, SCCH, SCFM, SCFH, SCMM, SCMH, LBPM, LBPH, GRPM, GRPH.

ADC/DAC RESOLUTION: 12 bits (0.025%).

DIGITAL COMMUNICATION STANDARD: RS-232.

Optional: Ethernet TCP/IP (HTML Server or TELNET Console).

RS-232 COMMUNICATIONS PARAMETERS: 8 bits, two stop bits, no parity (8,2,N).

RS-232 DATA TRANSFER RATE: 9600 baud.

CONTACT CLOSURES: Two sets of dry contact relay outputs for each channel (0.5A at

125 Vac, 1A at 24 Vdc).

BUZZER: Piezo Audio Indicator at 3.0 KHz, 85 dB activated by Alarm or Totalizer.

DIMENSIONS: Length: 7.75 inch (19.5cm), width: 6.75 inch (17cm), height: 4.5 inch

(11cm).

WEIGHT: 6.00 lbs (1.8kg).

TRANSDUCER INTERFACE CABLE: Flat cable with 15 pin “D” connector on the ends

is standard for AFC series mass flow controllers. Optional round shielded cable is available with male/female “D” connector ends for customer's mass flow meters or controllers. [Cable length may not exceed 9.5 feet (3 meters)].

RELAYS PORT CABLE: Optional shielded cable with female 25 pin “D” connector to connect to command module relays port.

DATA PORT CABLE: Optional shielded cable with male 25 pin “D” connector to connect to command module data port. [Cable length may not exceed 9.5 feet (3 meters)].

d.1 CE Compliance

Any SDPROC are in compliance with the below stated test standards currently accepted.

EMC Compliance with 89/336/EEC as amended; CE COMPLIANCE: EN 50011:1998 Group 1, Class A August 1999 for emissions; EN 61000-6-1:2001 for immunity.

(e) OPERATING INSTRUCTIONS

There are four buttons on the front panel of the SDPROC from which all functions can be controlled or set. These are labeled “ESC”, “UP”, “DOWN”, and “ENTER”.

Figure e-1, Control Panel for SDPROC.

e.1 Preparation and Warm Up

It is assumed that the SDPROC and the Mass Flow Meter(s) and/or Controller(s) have been correctly installed as described in this and the AFM/AFC/DFC/GFM/GFC manuals.

Turn the POWER switch to the ON position. A start up display will be briefly visible, and will display the type SDPROC configuration for the given unit. Remember to allow for proper warm up time by the mass flow transducer.

e.2 Single Channel SDPROC

e.2.1 Start up Display

Switching the power ON, the following will be shown on the display at the front of the SDPROC.

e.2.2 Main Display

After a few seconds, the Start up display will clear and the Main Display will appear.

This display will remain active until the power is turned off or any button is pressed.

The Main Display will indicate the following info:

= “F” current flow rate in % F.S. (NOTE: An “I” is indicated on the display

immediately following the displayed flow when the SDPROC is set for internal reference and “E” for external reference.)

= “S” current set point in % F.S. = “V” valve status by displaying a “CLS” for CLOSE, “OPN” for OPEN or

“AUT” for AUTO.

= “A” alarm status by displaying a “D” for disabled, “N” for no alarm events,

“L” for Low alarm and “H” for High alarm.

= “TOTAL” totalizer reading in current (volume/mass based) Engineering Units.

Readings are linear 0 to 100% of full scale. Direct engineering units are available on another screen. A proportionally linear 0 to 5 VDC or 4 to 20 mA output signal may be monitored simultaneously at the 25 pin “D” connector at the rear of the SDPROC (see section b.2.4). Press the Down button under the Main Display screen, to set the GENERAL, ALARM, TOTALIZER and PROGRAM settings (see section e.2.6).

e.2.3 Control Mode Status

There are three modes of operation that the mass flow controller can be set for. CLOSE will shut off the power to the mass flow controller valve, allowing the valve to mechanically close. OPEN will provide maximum power to the valve to allow it to open fully. This mode is used when there is a need to purge the gas flow system. AUTO mode will allow the mass flow controller to maintain a given flow as set by the user. In order to change mode of operation press the Esc button from the Main Screen. The following display will appear.

Valve Control Display for 1 channel SDPROC

To operate the mass flow controller in CLOSE, OPEN or AUTO modes, press the button (UP, DOWN, ENTER respectively) directly below the mode shown on the display (see section e.4.2). After pressing the button the Main Display will appear and indicate the current valve status by displaying a “CLS” for CLOSE, “OPN” for OPEN, or “AUT” for AUTO shown after the set point value.

Press the ENTER button under the Main Display screen, to set the desired flow for AUTO control.

e.2.4 Setpoint Display

The following display is shown when adjustments to the set point reference signal are desired.

Set Point Display for 1 channel SDPROC

The UP button under the “+” and DOWN button under the “-” will increase and decrease the set point respectively. Once set, press the ENTER button under EXIT on the display to return to the Main Display. This set point is only applicable when the SDPROC is used in INTERNAL REFERENCE mode. From the Set Point Screen in order to change the mode of operation press the Esc button under VALVE on the display. The following display will appear.

Valve Status/Flow Display for 1 channel SDPROC

To operate the mass flow controller in CLOSE, OPEN or AUTO modes, press the button (UP, DOWN, ENTER respectively) directly below the mode shown on the display. First line on the Display screen indicates the current valve status and flow rate in selected engineering units. Pressing the Esc button from the Valve Status/Flow Display will display Totalizer/Alarm Screen.

e.2.5 Totalizer/Alarm Display

Totalizer/Alarm Display for 1 channel SDPROC

The first line of the Totalizer/Alarm screen indicates the totalizer reading in current (volume/mass based) Engineering Units. The second line shows alarm status by displaying a “D” for disabled, “N” for no alarm events, “L” for Low alarm and “H” for High alarm. The totalizer can be reset to zero by pressing the Down button under RESET on the display. Press the ENTER button under EXIT on the display in order to return in to the Main Display screen.

e.2.6 Setup Channel Display

Pressing the Down button under the Main Display screen (see section e.2.2) will display SETUP CHANNEL screen shown below.

Setup Channel screen allows to configure:

= General device settings: Int./Ext. Reference, Gas density, Engineering Units,

Full Scale Flow in L/Min and Relays assignment.

= Alarm Properties: Mode, High and Low settings in % F.S., Delay Time, Action. = Totalizer Properties: Mode, Start Flow, Stop Volume, Action. = Program Properties: Batch parameters and Timer Settings.

Press the Esc button under GENER. on the display in order to make General settings. The following Internal/External/Program Reference display will appear.

e.2.6.1 Internal/External/Program Reference

The INT/EXT/PRG refers to point of origin for the valve control reference signal. To change this, press the button UP, DOWN, ENTER respectively. In the internal reference mode, the control signal is set by the user with the SDPROC controls (see section e.2.4).

Pressing the ENTER button on the front panel under PRG on the display of the SDPROC will toggle the reference between PROGRAM BATCH and PROGRAM TIMER. When complete with settings, press the ESC button under EXIT on the display, to go to the Density screen. The following Setup Gas Density Display will appear.

e.2.6.2 Setup Gas Density Display

The proper settings of the gas density (in grams per liter) are required for mass based engineering units (LBPH, LBPM, GrPH, GrPM). Press the ENTER button under (--->) on the display, to move the flashing cursor to the desired position. Pressing (+) or (-) will increment or decrement the particular digit respectively. The numbers will change from 0 to 9 and next to decimal point (.). Pressing (+) button one more time will change highlighted position of the cursor back to 0. The same is true in backward direction when pressing the (-) button. Only one decimal point is allowed. If changing position of the decimal point is required, change decimal point to any desired digit, next move cursor to the required position and adjust it to the decimal point with (+) or (-) button.

When complete with gas density settings, press the ESC button under NEXT on the display, to go to the Engineering Units screen. The following Setup Engineering Units Display will appear.

e.2.6.3 Setup Engineering Units Display

Press the UP or DN button, to change current engineering units. The following engineering units are supported: %F.S., SLPM, SLPH, SCCM, SCCH, SCFM, SCFH, SCMM, SCMH, LBPM, LBPH, GRPM, GRPH. If no more settings are required, press the ENTER button under EXIT on the display, to go back to the Main Display. Press the ENTER button under NEXT on the display in order to go to the Full Scale Flow Rate screen. The following Setup Full Scale Flow Rate Display will appear.

e.2.6.4 Setup Full Scale Flow Rate Display

The proper settings of the Full Scale Flow Rate (in liters per minute) are required for any engineering units except % F.S. If for example a mass flow controller used with SDPROC is calibrated for 200 SCCM, the value of 0.2 has to be set. Press the ENTER button under (--->) on the display, to move the flashing cursor to the digit, which has to be adjusted. Pressing (+) or (-) will increment or decrement the particular digit respectively. The numbers will change from 0 to 9 and next to decimal point (.). Pressing (+) button one more time will change highlighted position of the cursor back to 0. The same is true in backward direction when pressing the (-) button. Only one decimal point is allowed. If changing position of the decimal point is required, change the decimal point to any desired digit, next move cursor to the required position and adjust it to decimal point with the (+) or (-) button. When complete with Full Scale Flow Rate settings, press the ESC button under NEXT on the display, to go to the Relays Assignment screen. The following Setup Relays Assignment Display will appear.

e.2.6.5 Setup Relays Assignment Display

Two sets of dry contact relay are available for each channel. Each relay individually can be assigned for:

= NO ACTION = ALARM LOW = ALARM HIGH = TOTALIZER STOP

Press UP or DN button to change relay assignment. When complete with first relay settings, press the ESC button under NEXT on the display, to go to the second relay.

The following display will appear.

Press ESC button under NEXT on the display or the ENTER button under EXIT on the display, to go back to the Main Display.

e.2.7 Setup Alarm Display

Before enabling the Alarm make sure all alarm settings are configured properly. High and Low alarm values have to be entered in %F.S. engineering units. ALARM conditions become valid when the difference between current readings and installed set points is equal or more than corresponding values of high and low alarm levels. From the Setup Channel Display (see section e.2.6) press the Up button under ALARM on the display in order to make Alarm settings. The following display will appear.

e.2.7.1 Setup Alarm Mode Display

To change Alarm Mode in ENABLED or DISABLED, press the button (UP, DOWN respectively) directly below the mode shown on the display. Press the ENTER button under EXIT on the display, to go back to the Main Display. Press the ESC button under NEXT on the display to go to the Alarm Low settings. The following display will appear.

e.2.7.2 Setup Alarm Low Display

Pressing (+) or (-) will increment or decrement Low Alarm settings per 0.1% F.S. respectively. If no settings required for High Alarm press the ENTER button under EXIT on the display, to go back to the Main Display. Press the ESC button under NEXT on the display to go to the Alarm High settings. The following display will appear.

e.2.7.3 Setup Alarm High Display

Pressing (+) or (-) will increment or decrement High Alarm settings per 0.1% F.S. respectively. If no settings are required for High Alarm press the ENTER button under EXIT on the display, to go back to the Main Display. Press the ESC button under NEXT on the display to go to the Alarm Delay settings. The following Setup Alarm Delay Display will appear.

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