Micro Motion Manuals & Guides: Brooks Microprocessor Control and Read Out Unit | Micro Motion Manuals & Guides

Installation and
Operating Manual

Brooks Microprocessor
Control & Read Out Unit

Models 0152/0154

Partnumber 541-C-052-AAG Rev. I
January 2002

1

Dear customer

This product you have just received is of the highest quality available, offering
superior performance to the user. This controller provides the finest degree of
accuracy, repeatability and widest operating parameters available for extremely
reliable measurement and control.
In view of the wide variety of applications for mass flow measurement and control,
we have expressly designed this instrument to provide user selectable functions in
a single instrument to meet ever changing process conditions. Additionally, this
“state-of-the-art” design has been packaged and materials were selected to permit
application to a variety of often corrosive and hostile conditions.
To realize the full potential of the inherent design flexibility and ease of maintenance,
may we request you to review this manual in its entirety.
Should you need additional information concerning the 0152 and 0154 Series
Read-out Controllers, please feel free to contact your local Brooks Sales Office,
Representative, or the factory. We are pleased to have this opportunity of servicing
you for your liquid measurement and control needs and hope that we will be able to
help you further in the future.

Sincerely,
Brooks Instrument

CAUTION:
This instrument contains electronic components that are susceptible to
damage by static electricity. Proper handling: procedures must be observed
during the removal, installation or other handling of internal circuit boards or
devices.

HANDLING PROCEDURE:

1. Disconnect power to the unit.

2. Personnel must be grounded, via a wrist strap or other safe, suitable means,
before any printed circuit card or other internal device is installed, removed or
adjusted.

3. Printed circuit cards must be transported in a conductive bag or in another
conductive container. Boards must not be removed from protective enclosure
until the immediate time of installation. Removed boards must be placed
immediately in protective container for transport, storage or return to factory.

Comments:
This instrument is not unique in its contents of ESD (electrostatic discharge)
sensitive components. Most modern electronics designs contain components that
utilize microprocessor technology (e.g. CMOS). Experience has proven
that even a small amounts of static electricity can damage or destroy these devices.
Damaged components, even though they appear to function properly, exhibit early
failure.

WARNING (for translation of warnings, see appendix D)

Symbols used on the equipment are:

Caution ( Refer to accompanying documents ):
This Installation and operating manual must be read in its entirety before

performing any operation on the equipment. Failure to understand and follow
these instructions could result in serious personal injury and/or damage
to the equipment.

Protective Conductor terminal:
the protective conductor terminal is an important safety measure of the

instrument. Improper earthing of the
instrument will impair electrical safety significantly and could result in serious

personal injury from electric shock.
Caution, risk of electric shock:
Internal components may be hazardous life. Disconnect power before

removing cover from the equipment. Any operation requiring power to the
equipment with the covers removed, must be performed by trained and
qualified personnel.
Failure to observe this warning may cause serious personal injury from electric

Should the instrument require repair or adjustment, contact the nearest Brooks
Sales Office. It is important that servicing be performed only by trained and
qualified personnel. If the instrument is not properly serviced, serious personal

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injury and/or damage to the instrument could result.

shock.

Contents

1 Introduction..................................................................................................................................... 5

1.1 General Description .......................................................................................................... 5

2 Installation ...................................................................................................................................... 6

2.1 Receipt Of Equipment........................................................................................................ 6

2.2 Recommended Storage Practice ....................................................................................... 6

2.3 Installation Instructions ...................................................................................................... 6

2.3.1 Dimensions Of Enclosures ................................................................................. 6

2.3.2 Ventilation Requirements.................................................................................... 8

2.3.3 Cleaning Instructions .......................................................................................... 8

2.3.4 Cable Requirements ........................................................................................... 9

2.3.5 Replacement Of The Mains Fuses...................................................................... 9

2.3.6 Connector Pinning .............................................................................................. 9

2.3.7 Jumper Settings And Functions......................................................................... 11

2.3.8 Adjustments Of LCD Contrast And 5v Reference ...............................................12

3 Operation (manualy) .....................................................................................................................13

3.1 General.............................................................................................................................13

3.2 Description Of The Keys ...................................................................................................13

3.2.1 Channel Selection .............................................................................................13

3.2.2 Menu.................................................................................................................13

3.2.3 Up / Down .........................................................................................................13

3.2.4 Enter .................................................................................................................14

3.2.5 Blending ............................................................................................................14

3.2.6 Valve..................................................................................................................14

3.2.7 Control...............................................................................................................14

3.3 Start Up Screens ..............................................................................................................15

3.4 Changing The Active Channel ...........................................................................................15

3.5 Changing The Setpoint Value ............................................................................................ 15

3.6 Using The Blending Mode .................................................................................................16

3.7 Using The Valve Control Function......................................................................................17

3.8 Using The Remote Function..............................................................................................18

3.9 Menu ................................................................................................................................19

3.9.1 Changing The Engineering Units ........................................................................19

3.9.2 Full Scale Values...............................................................................................20

3.9.3 Display Format ..................................................................................................20

3.9.4 T otalizer Function ..............................................................................................21

3.9.5 Alarms Function ................................................................................................22

3.9.6 Start-up preference ............................................................................................22

3.9.7 Set I/O range .....................................................................................................22

3.9.8 Software version ................................................................................................23

4 Operation (via Personal Computer)..............................................................................................24

5 Specification ..................................................................................................................................25

6 Accessories .....................................................................................................................................27

6.1 Connecting Flomega Series ..............................................................................................27

6.2 Connecting Mass Flow And Pressure Series ....................................................................27

6.3 Connecting Smart Series ..................................................................................................27

6.4 RS-232 Communiction ......................................................................................................27

7 APPENDIX A Return Shipment And Guarantee...........................................................................2 8

7.1 Guarantee .........................................................................................................................28

7.2 Return Shipment ...............................................................................................................28

8 APPENDIX B Repair And/Or Warranty Request Sheet...........................................................29

9 APPENDIX C Available Engineering Units ..............................................................................30

10 APPENDIX D Blending Examples ............................................................................................31

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1 1 APPENDIX E Translations Installation Instructions.................................................................32

10. 1 Cable requirements for compliance with the EMC Directive.............................................32

10. 2 Safety Requirements for compliance with the Low Voltage Directive..................... ...........37

12 MODELLISTING .............................................................................................................................39

Contents

T able 1: Pinning Of Channel 1..4 Connectors .................................................................................................10

T able 2: Pinning Of Ext. V alve Control Connector ............................................................................................10

T able 3: Pinning Of Remote Connector............................................................................................................10

T able 4: Pinning RS-232 connector..................................................................................................................10

T able 5: Jumper Settings For 0-5Vdc I/O.........................................................................................................11

T able 6: Jumper Settings (Optional I/O Board Installed)...................................................................................12

Figure 1: Model 0152 ....................................................................................................................................... 5

Figure 2: Model 0154 ....................................................................................................................................... 5

Figure 3: Dimensions 1/2 19" Cassette ............................................................................................................ 7

Figure 4: Mounting Of 1/2 19" Cassette Into 19" Rack...................................................................................... 7

Figure 5: Dimensions Desk T op Housing.......................................................................................................... 7

Figure 6: Mounting Of Panelmount Unit............................................................................................................ 8

Figure 7: Dimensions Panel Cutout .................................................................................................................. 8

Figure 8: Backpanel Layout.............................................................................................................................. 9

Figure 9: Mainboard: Jumper And Potmeter Locations .................................................................................... 11

Figure 10: Optional I/O Board: Jumper Locations ...........................................................................................12

Figure 1 1: Labview...........................................................................................................................................24

Figure 12: T estpoint.........................................................................................................................................24

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1 INTRODUCTION

1.1 General Description

The Brooks microprocessor-based Control and Read Out Equipment has
been designed to meet the highest industry standards with user-friendly
operation as a primary requirement. Two channels for model 0152, and four
channels for model 0154 are available. Both models consist of a 1 /2 19”
rack cassette (3HE x 42 TE) with three housing options: Table T op with
optional handgrip, panelmount or 19" rack.

The models are designed for Brooks mass flow meters or controllers for
liquid and gas flow applications, and gas pressure applications.
Both + 15 or +24 Vdc secondary power supply modules are available.
The 0152/0154 is designed with 0-5Vdc input and output signals. These
analog signals represent the flowrate, from meters and controllers, and the
setpoint to controllers. The scaling is from 0% (0Vdc, no flow or pressure) to
100% (5Vdc, maximum calibrated flow or pressure). The readout also
supports other input and output signal ranges like: 0-10Vdc, 0-20mA and 4­20mA.
In that case an optional I/O board is installed.

Up to four (4) 15-pins connectors on the back panel are available to connect
the different Flow and Pressure Meters/Controllers
The instantaneous - two or four channels - read out function is

realized by a 4x20 character liquid crystal display provided with back
lighting, which ensures easy reading.

Figure 1: Model 0152

Features include membrane push buttons for setpoint, blending, valve
override and local/remote control. The selected functions are clearly pro­jected on the display . Percentage full scale or actual reading of flow/pres­sure units can be programmed on each channel via the Menu membrane
push buttons.
The models 0152 and 0154 can be operated either with independent Mass
Flow Control Channels, where flowrate is set through the Setpoint push
buttons, or with one or more channels slaved to the master (blending mode).
Each channel can be operated as master or slave, or in an independent

control mode.
As an option Brooks can provide software enabling the operator to control
Model 0152/0154 via a personal computer. This enables the user to connect
analogue (or digital devices with analogue I/O) devices to the 0152/0154 and
control these units a personal computer (see section 4).

The Control & Read out Unit has a valve override function. In the valve open
or close mode the controller valve will be driven to the selected mode
independent of setpoint values. In addition during valve open or close
situations, the setpoint can be changed to prepare the MFC for the follow­on process demands. In “control mode”, the controller valve is controlled
again by the setpoint provided to the MFC. The valve control function can
be overruled via the “Ext. valve Control” Sub-D connector.
The Control & Read out Unit also has a local control function. The local
control function is useful in permitting back-up of the customer’s system
configuration. In local mode, the Mass Flow Controllers will be operated
directly by the 0152 or 0154 series, while in the remote mode the custom­er’s (own) peripheral Equipment determines the control actions. The Mass
Flow Controller Output Signals are switched to the 25-pin connector located
on the backpanel. This connector includes up to 4 channels with setpoint
input and flowrate or pressure output.

Figure 2: Model 0154

Designed for use with:

• Gas TMF Controller models 5850*,5851*, 5853*, 5964*, 5965*, ...

• Gas TMF Meter models 5860*, 5861*, 5863*, 5864*, ...

• Pressure Controller 5866*

• Liquid Flomega Controller-Models 5881, 5882

• Liquid Flomega Meter-models 5891 5892

*Includes: E-, i-, “S”, MF -series.

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2 INSTALLATION

2.1 RECEIPT OF EQUIPMENT

When the equipment is received, the outside packing case should be
checked for any damage occurred during shipment.
If the packing case is damaged, the local carrier should be notified at
once regarding his liability . A report should be submitted to the local
Sales Office or factory .

Remove the envelope containing the shipping list. Carefully remove the
equipment from the packing case. Make sure spare parts are not dis­carded with the packing material. Inspect for damaged or missing parts.

2.2 RECOMMENDED STORAGE PRACTICE

If intermediate or long term storage is required for equipment, as supplied
by Brooks Instrument, it is recommended that sold equipment is stored in
accordance with the following:

1. Within the original shipping container .

2. Stored in a sheltered area, preferably a warm dry heated warehouse.

1. Ambient temperature 21°C (69.8°F) Nominal.
Minimum 7°C (44.6 °F)
Maximum 32°C (89.6°F).

2. Relative humidity 45% nominal
(Minimum 25%, Maximum 60%).

Upon removal from storage, a visual inspection should be conducted to
verify the condition of equipment “as received”.

2.3 INST ALLATION INSTRUCTIONS

2.3.1 DIMENSIONS OF ENCLOSURES

All housing options consist of a standard 1/2 19"
cassette ( 3HE x 42TE ) using three different parts:

• Desktop option: Desktop Housing

• 19" Rack option: 19" Rack

• Panelmount option: Bracket Set

The dimensions of the 1/2 19" cassette are:
cassette ( 3HE x 42TE ) using three different parts:

• Desktop option: Desktop Housing

• 19" Rack option: 19" Rack

• Panelmount option: Bracket Set

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The dimensions of the 1/2 19" cassette are:

Figure 3: Dimensions in mm of 1/2 19” Cassette

The cassette can be mounted directly into a 19" rack:

Figure 4: Mounting of 1/2 19” Cassette into 19” Rack

The cassette can be mounted into the desk top enclosure in the same
way . The dimensions of the desk top housing are (all dimensions in mm):

Figure 5: Dimensions in mm of the Desk Top Housing

7

The panelmount option uses the cassette mounted into a panel using the
panelmount bracket set. The dimensions for the panel cutout and the
mounting details are:

Figure 6: Mounting of Panelmount unit

Figure 7: Dimensions in mm of the Panel Cutout

2.3.2 VENTILA TI ON REQUIREMENTS

The ventilation holes of the instrument must never be blocked or covered.
When installing the instrument in a panel or a rack, always take care that
proper ventilation is provided.

For translations of this instruction, see appendix D

2.3.3 CLEANING INSTRUCTIONS:

Do not use cleaning agents other than water because this might affect
color and marking of the equipment.
Use a clean, soft and damp cloth for cleaning.

For translations of this instruction, see appendix D

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2.3.4 CABLE REQUIREMENTS

For compliance with the EMC directive 89/336/EEC, the equipment has
to be installed with shielded signal cables which are overall completely
screened with a shield of at least 80 %. Sub-D connectors used must be
shielded with a metal shield. The cable screen should be connected to
the metal shell and shielded at both ends over 360 Degrees. The shield
should be terminated to earth ground.

Always use a power cord that is certified or approved by a recognized
national test lab. The powercord must accomodate 3 conductors with a
wire size of at least 0.75mm2 (or 18AWG). One of the three conductors
has to provide the protective conductor function. The voltage range must
be suitable for the used mains voltage.
Additional earthing can be done by means of the external protective
conductor terminal marked with the symbol as shown below:

WARNING:

Protective Conductor Terminal

The protective conductor terminal is an important safety
measure of the instrument. Improper earthing of the instrument will
impair the electrical safety significantly and could result in serious
personal injury from electric shock.

For translations of this instruction, see appendix D

2.3.5 REPLACEMENT OF THE MAINS FUSES:

Caution, risk of electric shock
First disconnect power from the mains before replacing the fuses.

Two fuses are located in the power entry at the backside of the
instrument. Remove the fuses by pulling out the fuse cartridge. The fuses
must be replaced by fuses meeting the following requirements:

Dimensions: 5 x 20mm
Current: 2A T (slow blow)
Voltage: Suitable for mains voltage
Approvals: Certified or approved by a

recognized national test lab

For Europe: Breaking Capacity: 1500A

Melting Characteristic:IEC127

For translations of this instruction, see appendix D

2.3.6 Connector Pinning

Figure 8: Backpanel Layout

9

Table 1: Pinning of Channel 1..4 connectors

pin
number

Input/
Output

Function

1 Output +15Vdc/+24Vdc*
2 Input Flow mA
3 Output Setpoint mA
4nc Nc
5 Output Setpoint Volt
6 Setpoint ground
7 Output Valve override
8 Flow ground
9 reserved Reserved
10 Input Flow V
11 nc Nc
12 Power ground
13 Output +15Vdc/+24Vdc*
14 Output -15Vdc/nc*
15 nc Nc

*Depending on model: +24Vdc: only combination +24Vdc and power ground. ±15Vdc: only combination +15Vdc and -15Vdc
When applying non Brooks cables for use of Digital MFC/M’s (incl. MF) on mA I/O, pin 3 and 5 should be shorted at the read out side

Table 2: Pinning of Ext. valve Control connector

pin
number

Input/
Output

Function

1 Input Remote valve override channel 1

2nc Nc
3 Input Remote valve override channel 2
4nc Nc
5 Input Remote valve override channel 3
6nc Nc
7 Input Remote valve override channel 4
8nc Nc
9 Output +15Vdc/+24Vdc*
10 nc Nc
11 n c Nc
12 nc Nc
13 nc Nc
14 nc Nc

*Depending on model: +24Vdc: only combination +24Vdc and power ground. ±15Vdc: only combination +15Vdc and -15Vdc

15 Output -15Vdc / Power ground*

Table 3: Pinning of Remote connector

pin
number

Input/
Output

Function

1 Output Flow Volt channel 1
2 Output Flow mA channel 1
3 Output Flow Volt channel 2
4 Output Flow mA channel 2
5 Output Flow Volt channel 3
6 Output Flow Volt channel 4
7 Output Flow mA channel 3
8 Input Remote setpoint Volt channel 1
9 Input Remote setpoint Volt channel 2
10 Output Flow mA channel 4
11 Input Remote setpoint Volt channel 3
12 nc nc
13 Input Remote setpoint Volt channel 4
14 Flow ground channel 1
15 Input Remote setpoint mA channel 1
16 Flow ground channel 2
17 Input Remote setpoint mA channel 2
18 Flow ground channel 3
19 Flow ground channel 4
20 Setpoint ground channel 1
21 Setpoint ground channel 2
22 Input Remote setpoint mA channel 3
23 Setpoint ground channel 3
24 Input Remote setpoint mA channel 4
25 Setpoint ground channel 4

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Table 4: Pinning RS-232- Connector

pin Input/ Function
number Output
1NC
2 TXD Transmitted data
3 RXD Received data
4NC
5 GN D Signal ground
6NC
7NC
8NC
9NC

Note 1: On each side of the cable (at the connectors) pin 7 and 8 are connected and pin 1, 4 and 6 are connected.
Note 2: Within the calbe receive and trainsmit are twisted

2.3.7 JUMPER SETTINGS AND FUNCTIONS

As a standard, the required I/O selections are done at the factory upon
ordering. When only 0-5Vdc inputs and outputs are required , no optional
I/O board has to be installed . In this case the connectors between main
board and optional I/O board must be jumpered according to the table and
picture below.
For use of input and output signals other than 0-5Vdc ( 0-10Vdc, 0-20mA
and 4-20mA), the optional I/O board has to be installed. This 4 channel
optional I/O board is mounted on top of the mainboard of the readout.
Each channel of the converter consists of a separate input ( flow or
pressure) and output ( setpoint ) converter.The range can be configured
separately for each channel by means of jumpers. No additional
adjustment of potentiometers is necessary .
The microprocessor board uses 0-5Vdc signals internally . As a result
Flow or Pressure inputs other than 0-5Vdc are first converted by the
optional I/O board from either 0-10Vdc, 0-20mA or 4-20mA to 0-5Vdc.
Setpoints to be generated by the readout are converted by the optional
I/O board from 0-5Vdc to either 0-10Vdc, 0-20mA or 4-20mA.

NOTE:

Care has to be taken when using mA I/O. Flow and setpoint
grounds of the instrument are high impedance to eliminate voltage
drop across long lines for Volt I/O. The high impedance ground
lines are not designed for sinking mA signals. Sinking mA signals
will result in faulty flow information.
Always connect the mA ground lines to power ground and connect
the readout’s high impedance ground lines to the same power
ground as well.
When Brooks Mass flow controllers and meters are connected, this
is automatically done at the controller or meter side.

Table 5: Jumper settings for 0-5Vdc I/O

Connector

Jumper positon
J 4 No jumpers necessary
J5 1-2,3-4,5-6,7-8
J6-J9 1-2,3-4,5-6

Figure 9: Mainboard: Jumper and Potmeter locations

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Table 6: Jumper settings (optional I/O board installed1)

Input Jx012)Jx022)Jx032)Jx042) Jx06 Jx102) Jx1 1
Output
0-5Vdc 1-2 1-2 1-2 1-2 off on off
0-10Vdc 1-2 1-2 1-2 1-2 on on on
4(0)-20mA

Note: The selection between 0-20 mA or 4-20 mA can be done via the menu function

1) Jumpers J4-J9 have to be removed before installing the optional I/O board

2) X denotes the channel number to which the jumper relates, eg for channel 1: X=1

3) For i series: 2-3
For Flomega and pressure series 1-2
For digital series 1-2 or 2-3 (don’t care)

3)

2-3 2-3 2-3 o ff off off

2)

Figure 10: Optional I/O board: Jumper Locations

2.3.8 ADJUSTMENTS OF LCD CONTRAST AND 5V REFERENCE

The contrast of the Liquid Crystal Display can be adjusted by turning
potmeter R26 on the Mainboard.

The setpoint outputs of the readout use a 5Vdc reference. The reference
voltage can be checked by measuring between testpin 1 and 2 (TP1 and
TP2). The reference voltage must be 5.000 ± 0.001 Vdc and can be
adjusted by turning potmeter R29 on the Mainboard.

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